Study and Investigation of Analysis of Metal Matrix Composite

INTERNATIONALJOURNALOFMECHANICAL
ENGINEERINGANDTECHNOLOGY(IJMET)
ISSN09766340(Print)
ISSN09766359(Online)
Volume3,Issue2,May
August(2012),pp.171
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171
InternationalJournalofMechanicalEngineeringandTechnology(IJMET),ISSN0976
6340(Print),ISSN09766359(Online)Volume3,Issue2,MayAugust(2012),IAEME
Keywords
MetalMatrixComposite(MMC),CAD/CAM,Powdermetallurgy,Casting,machining
process,mechanicaltesting
1.0INTRODUCTION
Thehistoryofdevelopmentofmetal,ceramic&carbonmatrixcompositesismuch
morerecentthanthatofthepolymermatrixcomposites.Initialresearchonthemetaland
ceramicmatrixcompositesarebasedoncontinuouscarbonorboronfibers,butthere
weredifficultiesinproducinggoodqualitycompositesduetoadversechemicalreaction
betweenthesefibersandthematrix.Withthedevelopmentofnewfibers,suchassilicon
carbideoraluminiumoxide,intheearly1980s,therehasbeenrenewedinterestandan
acceleratedresearchactivityindevelopingthetechnologyinbothmetalandceramic
matrixcomposites.Theinitialimpetusforthisdevelopmenthascomefromthemilitary
andaerospaceindustries,wherethereisagreatneedformaterialswithhighstrengthto
weightratiosorhighmodulustoweightratiosthatcanalsowithstandseverehigh
temperatureorcorrosiveenvironments.Presently,thesematerialsareveryexpensiveand
theiruseislimitedtoapplications thatcanusetheirspecialcharacters,suchashigh
temperatureresistanceorhighwearresistance.Withdevelopmentoflowercostfibers
andmorecosteffectivemanufacturingtechniques,itisconceivablethatbothmetaland
ceramicmatrixcompositeswillfindcommercialapplicationsinautomobiles,electronic
packages,sportinggoodsandothers[1].
The carbon matrix composites are more commonly known as carbon carbon
composites,sincetheyusecarbonfibersasthereinforcedforthecarbonmatrix.The
resultingcompositeshavealowerdensityhighermodulusandstrength,lowercoefficient
ofthermalexpansion,andhigherthermalshockresistancethanconventionalgraphite.
Thecarbonmatrixcompositeshavebeenusedasthermalprotectionmaterialsinthenose
capandtheleadingedgesofthewingofspaceshuttles.Theyarealsoinrocketnozzles
andexitcones,andaircraftbrakes,andtheirpotentialapplicationsincludeinpistonsin
internalcombustionengines,gasturbinecomponents,heatexchangersandbiomedical
implants.
METALMATRIXCOMPOSITES
TheMetalMatrixComposites(MMC)canbedividedintofourgeneralcategories:
1. Fiber reinforced MMC containing either continuous or discontinuous fiber
reinforcements;thelatterareintheformofwhiskerswithapproximately0.10.5
mindiameterandhavealengthtodiameterratioupto200.
2. ParticulatereinforcedMMCcontainingeitherparticlesorplateletsthatrangein
sizefrom0.5to100m.theparticulatescanbeincorporatedintothemetalmatrix
tothehighervolumefractionsthanthewhiskers.
3. DispersionstrengthenedMMCcontainingparticlesthatare<0.1mindiameter.
4. InsituMMC,suchasdirectlysolidifiedeutecticalloys.
172
In this article, we focus our attention on the first two categories, more specially on
whiskersandparticulatereinforcedMMCs.MoredetailedinformationontheMMCcan
befoundinreferences[25].
ContinuouscarbonorboronfiberreinforcedMMCshavebeenunderdevelopment
for>20years;theyhavebeenfoundlimiteduseduetoproblemsincontrollingthechemical
reactionbetweenthefibersandthemoltenmetalathighprocessingtemperaturesusedfor
suchcomposites.Theresultofthischemicalreactionisabrittleinterphasethatreducesthe
mechanicalpropertyofthesecomposites.Fibersurfacetreatmentsdevelopedtoreducethis
problemincreasethecostofthefiber.Additionally,themanufacturingcostofcontinuous
carbonorboronreinforcedMMCisalsohigh,whichmakesthemlessattractiveformany
applications.MuchoftherecentworkonMMCisbasedonsiliconcarbidewhiskers(
)
orsiliconcarbideparticulates
).SiCislesspronetooxidativereactionsatthenprocessingtemperatureused.
Furthermore,notonlytheyarelessexpensivethancarbonorboronfibers,butalsothey
canbeincorporatedintometalmatricesusingcommonmanufacturingtechniques,suchas
powdermetallurgyandcasting.
2.0LITERATUREREVIEW
ComprehensiveliteraturereviewcanbefoundinZhihongGUO,HuaHOU,Yu
hongZHAO,ShuweiQU[6],ThesqueezecastprocessparametersofAZ80magnesium
alloywereoptimizedbymorphologicalmatrix.Experimentswereconductedbyvarying
3
squeezepressure,diepreheattemperatureandpressuredurationusingL 9(3 )orthogonal
arrayofTaguchimethod.InTaguchimethod,a3levelorthogonalarraywasusedto
determinethesignal/noiseratio.Analysisofvariancewasusedtodeterminethemost
significantprocessparametersaffectingthemechanicalproperties.Mechanicalproperties
such as ultimate tensile strength, elongation and hardness of the components were
ascertainedusingmultivariablelinearregressionanalysis.Optimalsqueezecastprocess
parameterswereobtained.
Tamer Ozben, Erol Kilickap, Orhan akr [7]gives a primitive study forthe
results of experimental investigation on mechanical and machinability properties of
silicon carbide particle (SiCp) reinforced aluminium metal matrix composite. The
influenceofreinforcedratiosof5,10and15wt.%ofSiCponmechanicalproperties
wasexamined.Theeffectofmachiningparameters,e.g.cuttingspeed,feedrateand
depth of cut on tool wear and surface roughness was studied. It was observed that
increaseofreinforcementelementadditionproducedbettermechanicalpropertiessuchas
impacttoughnessandhardness,buttensilestrengthshoweddifferenttrend;increased
upto 10 wt.% of SiCp reinforced and then decreased when 15 wt.% of SiCp
reinforcementaddition.Machinabilitypropertiesoftheselectedmaterialwerestudied
and higher SiCp reinforcement produced a higher tool wear; surface roughness was
generallyaffectedbyfeedrateandcuttingspeed.
173
M.T.AbouElkhair,A.Lotfy,A.Daoud,A.M.ElSheikh[8]havementionedthe
impotantofZA27alloybasedcompositesweresynthesizedbystirringmethod,followed
bysqueezecasting.Stircastingwasemployedsuccessfullytoincorporate5vol.%of
porosity inthe
variousreinforcementparticulates,namely,SiC,ZrO2orC.The
compositeswasdecreasedbysqueezepressure.Thepresenceof
particles and/or
applicationofsqueezepressureduringsolidificationresultedinconsiderablerefinement
inthestructureofthecomposites.Themicrostructures,Xraydiffraction(XRD)and
energydispersiveXrayanalysis(EDXA)resultsindicatedthatnosignificantreactions
occurredattheinterfacebetweentheSiCorCparticlesandZA27alloy.However,in
caseofZrO2 reinforcedZA27,theZrO2 reactedwithCupresentinthemoltenZA27
alloy,formingCu5Zr.Thermalanalysisshowedthatbothandnucleationandgrowth
temperaturesofthecompositeswerelowerthanthoseoftheZA27alloy.Thepresenceof
particles in the ascast or squeezed composites led to not only an accelerated age
hardeningresponse,butalsoanincreaseinthepeakhardnessofthecomposites.The
valuesofcoefficientofthermalexpansion(CTE)ofthecompositesweredrastically
lowerascompared
to thoseof the ZA27alloy. The tensile properties ofthe
compositesdecreased as aresultof the additionof the particles. Scanning electron
microscope(SEM)picturesofthecompositesindicatedthatcracksmainlyinitiatedat
particlematrixinterface,propagatedthroughthematrixandlinkedupwithothercracks
leadingtofailureofthecomposites.
Examining from the perspective of investigation for composite manufacture,
T.P.D.Rajan,R.M.Pillai,B.C.Pai,[9]Thepresentinvestigationisoncharacterizationof
functionallygradedcompositesbasedon356castand2124wroughtaluminumalloys
reinforcedwithSiCparticlesof23maverageparticlesizeprocessedbyliquidmetalstir
casting followed by horizontal centrifugal casting. A maximum of 45 and 40% SiC
particles are obtained at the outer periphery of the Al(356)SiC and Al(2124)SiC
FGMMCcastingrespectively.Themaximumhardnessobtainedattheouterperiphery
afterheattreatmentforAl(356)SiCandAl(2124)SiCFGMMCare155BHNand145
BHNrespectively.Thefreezingrangeofthematrixalloyhasbeenfoundtodictatethe
nature of transition from particle enriched to depleted zone. These composites are
suitableformakingengineeringcomponents,whichrequireveryhighsurfacehardness
andwearresistanceswithhighspecificstrength.
MohsenMasoumi,HenryHu[10]givesabriefsummaryaboutthepaperreports
theeffectofappliedpressureonthetensilepropertiesandthemicrostructureofsqueeze
castMg5wt.%Al1wt.%Ca(AX51)alloy.Inthisstudy,appliedpressuresfrom3to
90MPawereconsidered.Itwasobservedthatthefractionofsecondphasesandporosity
levelreduceswithanincreaseinappliedpressure.Thetensiletestsresultsindicatethat
ultimatetensilestrength(UTS),yieldstrength(YS)andelongation(Ef)ofAX51alloy
increasewithincreasingappliedpressures.Theimprovementintensilepropertieswas
attributedtothecastingdensificationandpresenceofhigheramountofsoluteinthe
matrix.Thescanningelectronmicroscopy(SEM)fractographsrevealthatthefracture
modesofthesqueezecastalloyismoreductileathigherappliedpressures.Thecrack
initiationoccurredmostlyinthevicinityofMgAlCaparticles.
174
S.Gopalakrishnan,N.Murugan[11]addressedMetalmatrixcomposite(MMC)
focusesprimarilyonimprovedspecificstrength,hightemperatureandwearresistance
application. Aluminum matrix reinforced with titanium carbide (AlTiCp) has good
potential.Themainchallengeistoproducethiscompositeinacosteffectivewaytomeet
theaboverequirements.InthisstudyAlTiC pcastingwithdifferentvolumefractionof
TiCwasproducedinanargonatmospherebyanenhancedstircastingmethod.Specific
strengthofthecompositehasincreasedwithhigher%ofTiCaddition.Dryslidingwear
behaviorofAMCwasanalyzedwiththehelpofapinondiscwearandfrictionmonitor.
Thepresentanalysesrevealtheimprovedspecificstrengthaswellaswearresistance.
S.H. Chen, P.P. Jin, G. Schumacher, N. Wanderka[12] developed the
microstructureandinterfaceofanMg2B2O5 whiskerreinforcedmagnesiumcomposite
werecharacterizedusingopticalmicroscopy,transmissionelectronmicroscopyandX
raydiffraction.ItwasfoundthattheMg2B2O5 whiskershaveatwinnedstructurewith
the(202)asthetwinplaneandgrowthdirectionalong[010].TheMgB 4O7particles
andtheglobularMg2SiparticleswereobservedwithintheMg2B2O5whisker,andatthe
interfacebetweentheMg2B2O5 whiskersandMgmatrix,respectively.TheMgOand
MgB2 phase formed at the matrixwhisker interface during vacuumgas pressure
infiltration process due to the interfacial reaction. The crystallographic orientation
relationshipsbetweentheMg2B2O5whiskerandthe
inter
faci
al
reac
tion
pro
duct
s
wer
e
[110]MgO//
fou
nd
to
be
,
and
//[1
1
0]M
//(002)MgOand
gO(002)
MgO//
respectively.ThefactorsthatinfluencethemicrostructureoftheMg 2B2O5whiskersand
theformationoftheinterfacialreactionproductsofMg 2Si,MgOandMgB2phaseswere
discussed.
M.S. Song, M.X. Zhang, S.G. Zhang, B. Huang, J.G. Li [13] developed TiC
ceramicparticulateslocallyreinforcedaluminummatrixcompositesweresuccessfully
fabricatedviaselfpropagatinghightemperaturesynthesis (SHS)reactionofAlTiC
system during aluminum melt casting. The SHS reaction could be initiated when Al
contentsinthegreencompactsrangedfrom20wt.%to40wt.%.WithincreasingAl
contents,theignitiondelaytimewasprolongedandtheadiabaticcombustiontemperature
was lowered. Using XRD and DSC analysis, the SHS reaction characteristic was
discussed. The result showed that Al serves not only as diluents but also as an
intermediatereactantparticipatingintheSHSreaction,determiningthereactionprocess
anditsfinalproducts.TheSEMimagesrevealedarelativelyuniformdistributionand
nearlysphericalmorphologyofTiCparticulates inthelocallyreinforcedregion,and
excellent adhesion and gradient distribution between the TiC particulates reinforced
region and Almatrix. The size of the TiC particulates decreased obviously with
increasingAlcontentsintheblends.
ComprehensiveliteraturereviewcanbefoundinP.K.Rohatgi,A.Daoud,B.F.
Schultz, T. Puri [14] the feasibility of incorporating fly ash cenospheres in die cast
magnesiumalloyhasbeendemonstrated.Theeffectsofflyashcenosphereadditionson
themicrostructureandsomeofthesalientphysicalandmechanicalproperties
175
ofmagnesiumalloy(AZ91D)metalmatrixcompositeswereinvestigated.Thecontrol
AZ91D alloy and associated composites, containing 5, 10, and 15 wt. % of fly ash
cenospheres(added),weresynthesizedusingadiecastingtechnique.Amicrostructural
comparison showed that micro structural refinement occurred due to the fly ash
additionsandbecamemorepronouncedwithanincreaseinthepercentageoftheflyash
added.Themetalmatrixareasnearertotheflyashparticlesexhibitedagreaterdegreeof
refinementthanwasobservedintheareasfurtherawayfromtheseparticles.Bothfilled
andunfilledflyashcenospheres,andporositywereobservedinthemicrostructures.The
compositespecimendensitiesdecreasedandthecoefficientofthermalexpansiondidnot
changesignificantlyasthevolumepercentofflyashwasincreasedwithintherange
investigated.Thehardnessvaluesofthecompositespecimensexhibitedanincreasein
proportiontotheincreaseinpercentageofaddedflyash.Thetensilestrengthofthe
compositesalsoincreasedastheconcentrationofflyashcenosphereswasincreased.In
contrast, the Youngs modulus of these composite samples, as measured by non
destructivepulseechomethod,decreasedasthepercentageofflyashinthecomposite
was increased. SEM micrographs of the tensile fracture surfaces showed broken
cenospheresonthefracturesurfaceandevidenceofpullouts,whereflyashparticles
werepreviouslyembeddedinthematrix.Compressiontestingresultsshowedthatthe
presenceof5wt.%cenospheresdecreasedthecompressivestrengthandcompressive
yieldstrengthofthecompositerelativetothatoftheAZ91Dmatrixalloy.Surprisingly,a
significantchangeincompressionstrengthwasnotobservedforthecompositeswith10
and15wt.%cenospheresincomparisontotheAZ91Dmatrixalloy.Incontrasttothe
tensiletests,nocenosphereremnantswereobservedonthecompressivetestfracture
surfaceofthecomposites.Thisobservationsuggeststhatthefracture
of
thecompositewasinitiatedwithintheAZ91Dmatrixbynormalvoidnucleation
and
growth, followed by crack propagation through the matrix, avoiding any of the
cenospheres,leadingtocompositefractureofthematrix.
BarbaraPrevitali,DantePocci,CataldoTaccardo[15]havementionedtheimportant
ofthispaperisaimedatstudyingtheapplicationoftraditionalinvestmentcastingprocess
toobtaincomponentsindiscontinuouslyparticlereinforcedaluminummatrixcomposites
Usingthedoublestirmethod,amixedliquidslurryofaluminumalloyand20%SiCor
7.5%B4Ccarbideswasobtained.Asacasestudyacomponentfromthetextilesector
wasproducedinunreinforcedalloyandinbothcomposites.Thewearresistanceofthe
componentsinthethreedifferentmaterialswasranked.Moreover,analysisofparticle
distribution and optical and scanning electron microscope observations of reaction
productswerealsoperformed.ResultsshowthatcomponentsinaluminumalloywithSiC
asreinforcementhaveuniformdistributionofceramicparticles,soundinterfacewithout
fragilecompoundsandwearresistancehigherthanthatofcomponentsreinforcedwith
B4Cparticles.
3.0PROBLEMFINDINGSANDDISCUSSION
Metalmatrixcomposites(MMCs)haveemergedasanimportantclassofmaterials,
whichareincreasinglybeingutilizedinrecentyears.Applicationofthesematerialsin
certainareasislimitedduetodifficultiesinmachining.Theprincipalmachining
176
parameters that control machinability characteristics are extrinsic parameters (cutting

speed, feed rate, depth of cut, and type of cutting tools) and intrinsic parameters
(particulatesize,volumefraction,andtypeofreinforcement).Differentcuttingtoolsused
inmachiningthesematerialsaregivenintheorderofdecreasinghardnessasPCD,CBN,
TiC, Si3N4, Al2O3, Mg and WC. The present review is focused on the influence of
cuttingparameters,morphology,distribution,andvolumefractionofreinforcementon
thesurfacefinish,toollife,cuttingforces,andchipformation.Thisreviewwillprovide
aninsightintoselectingtheoptimummachiningparametersformachiningmetalmatrix
composites.
3.1Processflowanalysis
Fig1.ProcessflowanalysisofMetalMatrixComposite
Thefig1showsprocessofmetalmatrixcomposite.Itisdividedintofourmajor
areas like that design and analysis, mechanical testing properties, manufacturing and
machining.
3.2DesignandAnalysis
Designareaistodesigntheshapeandsizeofthecomponent.Nowadaysdesign
acomponentusingcad/caminterface.itisaeasilytooldesignacomponent.
CAD/CAM is technology both hardware and software and applications driven field.
Aerospace,automotiveandshipbuildingindustrieshaveinfluenced,togreatextent,the
developmentofloftedandsculpturedsurfaces.Thereforeunderstandingtheutilization
andimplementationoftheCAD/CAMtechnologyinanindustrialenvironmenthelpsto
close the gap between creating the technology, managing it, using it and more
importantlylearningit.Fig3.1Shows,inageneralsense,howatypicalCAD/CAM
system is utilized in a typical industrial environment. The fig 3.1 shows the major
components or packages that exist. The detailed capabilities and functions of each
packageaswellasthevarioustypesofexistinguserinterfacearewhatmakesthese
systemslookentirelydifferent.Asamatteroffact,practicalexperiencehasproventhat
learningonesystemissufficienttolearnanotheroneatamuchfasterpace.Thisfaster
paceisattributedtodealingwithsamefunctions.Alltheuserhastodoistoadjusttothe
userinterfaceandthemanagementhierarchyofthenewsystem.Onemightconcludethat
learningthegenericbasicconceptsbehindthesesystemsdoesnotonlyspeedupthe
177
trainingcurveofperspectiveusersbutitalsohelpsthemutilizethetechnology
productively[16].
Geometric modeling of conceptual design
Is design evaluation
is possible with
available software
Design testing and evaluation
Is final design
acceptable?
Drafting and Documentation

Process planning
Are there
manufacturing
discrepancies in
CAD databases?
NC Programming, Machining, Inspection and Assembly
Fig.2UtilizationofTypicalCAD/CAMSystemsinanindustrialenvironment
3.3MechanicaltestingProperties
Thefollowingtestconsiderscheckingthemechanicalproperties:
178
Tensile,compressionandbendingtests
TheTensile,compressionandbendingtestsarecarriedoutonauniversaltesting
machine with a capacity of200 tons or more. Tensile testing is more common than
compressiontesting,whichisdoneforalimitednumberofmaterialssuchasconcrete,
brick,ceramics,etc.apullingloadisappliedfortensilespecimenandcompressiveload
forcompressivetestpiece.Machinegivescontinuousrecordofloads,deformation,etc.to
helpsubsequentanalysisandcalculationofimportantquantitiesrelatingtotensileand
compressivestrength.Testproceduresandspecificationsfortestpiecearekeptasper
relevantstandards[17].
Hardnesstesting
Inselectingmaterialstowithstandwear,propertiesoftenconsideredarehardness
and toughness. Hardness enables the material to resist penetration and scratching.
Hardnessofametalcanbetestedbyseveralmethodsasbrinell,Rockwell,Vickers,shore
seleroscope.
Hardnessgivesageneralindicationofthestrengthofmaterialanditsresistanceto
scratching and wear. A relationship has been established between ultimate tensile
strength(UTS)andBrinellhardness(HB)forsteelsasfollows:
UTS(Mpa)=3.5(HB)
2
WhereHBisinkg/mm asmeasuredforaloadof3000kg.
HotHardnessistheHardnessofthematerialatelevatedtemperatureandisan
importantfactorconsideredformetalcuttingtools,diesusedforhotworkingoperations
andcastingoperations.
Hardenabilityisthemeasuretoresponseofametaltotheprocessofhardening.It
referstothedepthwithinaspecimenuptowhichappreciableHardnesscanbeattained.
Hardenabilityisdeterminedlargelybythepresenceofalloyingelementsinthehardened
metal.ItistestedbyJominyandQuenchhardenabilitytest.
BRINELLHARDNESS
Itisbasedontheareaofindentationasteelorcarbideballmakesinthesurfaceof
testingspecimenforagivenloadwhenloadedfor15sec.onferrousmetalsandupto
30sec.onnonferrousmetalsspecimen.Aftertheloadisreleased,thediameterofthe
spherical immersion made in the surface of the test piece is found using brinell
microscopeandtheBrinellhardnessnumber.
ROCKWELLHARDNESS
RockwellhardnessisamuchfastertestandisthetestalsoRockwellhardness
number is determined through an indentation made under a load. The indenter is,
however,muchsmallerinsize,anditcouldbeasteelballusedforsoftmetalsora
diamondconeusedforhardmetals.
179
IMPACTTEST
Many parts of a machine needed to bedesigned to stand impact loading and
absorbtheenergyofimpactwithinitthroughelasticaction,thus providingdamping
effect.Impacttestisdonetodeterminetheresistancetofractureagainstimpactloads.
Twotestsare1.Izodimpacttoughnesstest,2.Charpyimpacttoughnesstest.Energy
requiredtofractureanotchedspecimenismeasuredintestswheremeasuredenergyis
indicativeofrelativetoughnessofthematerial.
FATIGUETEST
Itisthephenomenonthatbeginswithaminutecrackinametal,which,undertheeffect
ofrepeated,getsdevelopedintoacrackleadingtosuddenunexpectedfailures.Fatigue
failure normally starts at the surface of the work piece. Where stress is higher.
Componentssubjectedtofatigueloadsaredesignedonthebasisoffatiguestrengthofthe
metal,whichisalwayslowerthantheyieldstrengthofthemetal.
3.4ManufacturingMethods
Anumberofcompositefabricationhavebeendevelopedthatcanbeplacedunder
the following categories. They are (1) powder metallurgical techniques (2) liquid
metallurgy(3)stircasting(4)squeezecasting.
THEPOWDERMETALLURGYPROCESS
Theconceptofmakingpartsfrommetalpowderissimpleandstraightforward;
however,thetechniquesemployedcanbeverysophisticated,requiringahighlevelof
technical competence and a substantial investment in capital equipment. The process
consistsofthreesteps:blending,compacting,andsintering[18].
Blending
Blendingistheprocessofpowderagitationforthepurposeofhomogenizingthe
particlesizes.Mixingalsotakesplaceandservestointerdispersepowdersofdifferent
chemicalcompositions.Alloyedpowders areproducedbycombiningahomogeneous
mixtureofcarefullyweighedandblendedpowders.
Lubricantsareaddedtothepowdertoreducefrictionbetweentheparticlesas
theyarebeingcompacted,aswellastoreducediewear.Stearicacid,lithiumstearate,or
powderedgraphitearetheprincipallubricantsused.Blendingisalmostuniversallydone
dry;however,insomefinelydividedaluminiumpowders,toreducedustandthedanger
ofexplosionorfire,theprocessisdonewet.
Compacting
Afterthemetalpowdershavebeenblendedtoachievevariousdesiredproperties,
theyarepressedorcompactedtotherequiredshape,size,anddensity.Metalpowders
presentproblemsofinternalfrictionwhenpressedinthedie.Bothdensityandstrength
180
decreaseinthepowdermassasthedistancefromthepunchincreases.Tominimizethis
condition,punchesareusedatbothendsofthedieasshowninfig.theuseoflubricants
improvesthedensity,minimizes theloadrequired,andincreaseslife,particularlyby
easingpartejection.However,lubricantscancreateproblemsinreducedgreenstrength,
infeedingthepowderintothedie,andinlubricantreaction.Lubricantsmustbedriven
offbyalowtemperaturestageheatingbeforesintering,
For high volume production, tungsten carbide is used as the die material.
Althoughthecostishigher,itwilloutwearthenormallyusedtoolsteelsbyaratioof
about10:1.Somecarbidediescanbeusedtoproduceamillionpartsbeforetolerances
2
areexceeded.Highpressures,sometimesinexcessof50tons/in .(689.5Mpa)areusedto
causemechanicalinterlockingbetweentheirregularitiesoftheparticles.
Thecompactionoperationconsolidatesanddandifiesthepowdersintowhatis
commonlytermedagreencompact.Thecompactwillbeveryclosetothesize,shape,
densityofthefinishedpart.Afterejectionfromthediethepartcanbehandled,butis
relativelyfragileinthegreenstateandifdroppedwillprobablycrack.
Therearetwomainmethodsofcompactingmetalpowders:(1)withapunchand
die,and(2)isostatically.Partgeometryisthemajorfactorindeterminingwhichmethod
istobeused.Ifthepartshapeissimple,mechanicalpressingislikelytobeused.Parts
withintricateconfigurationscanbemadebyisostaticcompactiondiscussedlater.
DieCompaction:Diecompactionislimitedtoverticalmotionsonly,sopartswith
backanglesareundercutscannotbemade.Foramechanicalpressoperatingonpowder
fill/compaction/ejectioncycleof3to4seconds,approximately1000componentscanbe
producedperhour.Forsimplerparts,theseoutputscanbeincreasedwithmultistation
rotarypresses,wheremultiplesetsoftoolsaremountedonarotarytable.Punchmotions
areactuatedbyfixed,horizontalcamtracksorrollers,andthepressesarecapableofvery
highoutputratesintheorderof35,000partsperhour.
Mechanical and Hydraulic Presses. Both mechanical and hydraulic types of
pressesareusedforcompacting.Theadvantagesandlimitationofeacharebrieflyas
follows.
Mechanicalpressesareoflowertonnage(usually200tonsorless)andhavefaster
cycles. Normally no dwell time is possible, although newer presses have clutches.
Compactingisdonetogivenheight,nottoagivenpressureordensity.
Hydraulicpressesareofhighertonnage(usually500tonsormore),haveslower
cycletime,evenwithaccumulators,andhaveinfinitelyvariabledwelltime.Partsmaybe
pressedtoagivenloadtoprovidegooddensitycontrol.Limitswitchesmaybeusedfor
heightcontrol.
SINTERING
Sinteringisthethirdstepinproducingpowderedmetalparts.Thegreencompacts
areheatedinmuffletypeorwiremeshconveyerbeltfurnace.Specialatmosphere,such
181
hydrogenordissociatedammonia,arerequiredforsinteringofferrousmetaltocontrol
bothcarburizationanddecarburizationofironandironrichcompacts.
Furnacetemperaturevarywiththesinteringrequirements;forbrass,atemperature
o
0
o
o
o
of 1600 to 1615 F (870 to 880 C)is satisfactory, and for stainless steel,2000 to
o
o
o
2350 F(1100 to1300 C)isused.Thetemperaturemustremainbetween60%to80%of
themeltingpointoftheprincipleconstituent.Thesinteringtimemayrangefrom20
minutestoanhourormore.Thelubricantsthatwereoriginallyblendedwiththepowders
arepermittedtoburnoffinaspecialchamberbeforethepartsreachthehighheatzoneof
thefurnace.
LIQUIDMETALLURGYROUTE:
Liquidstateprocessesincludestircastingorcompocasting,infiltration,spraycastingand
in situ(reactive) processing. Theselection oftheprocessing routedepends onmany
factors including type and level of reinforcement loading and the degree of micro
structuralintegritydesired.[conferencereference3]
STIRCASTING:
This involves incorporation of ceramic particulate into liquid aluminium melt and
allowingthemixturetosolidify.Here,thecrucialthingistocreategoodwettingbetween
theparticulatereinforcementandtheliquidaluminiumalloymelt.Thesimplestmost
commerciallyusedtechniqueisknownasvortextechniqueorstircastingtechnique.The
vortextechniqueinvolvestheintroductionofpretreatedceramicparticlesintothevortex
ofmoltenalloycreatedbytherotatingimpeller.Lloyd(1999)hasreportsthatvortex
mixingtechniqueforthepreparationoftheceramicparticledispersedaluminiummatrix
compositesareoriginallydevelopedbySurappaandRohatgi(1981)attheIndianinstitute
ofScience,Bangalore.Subsequently,severalaluminiumcompaniesfurtherrefinedand
modified the processes which are currently employed to manufacture a variety of
aluminiummetalmatrixcompositesoncommercialscale.
Thevortexmethodis oneofthebetterknownapproachesusedtocreateand
maintainagooddistributionofreinforcementmaterialinthematrixalloy.Inthismethod,
afterthematrixmaterialismelted,itisstirredvigorouslytoformavortexatthesurface
ofthemelt,andthereinforcementmaterialisthenintroducedatthesideofthevortex.
Thestirringiscontinuedforafewminutesbeforetheslurryiscast.
SQUEEZECASTING:
Thesqueezecastingprocessisactuallyacombinationofcastingandforging.A
preciseamountofmoltenmetalispouredintothebottomhalfofapreheateddiesetand
allowedtopartiallysolidify.Anupperdiethendescendsapplyingpressurethroughout
thedurationofsolidification.Intricateshapescanbeproducedatthatarefarlessthan
wouldnormallycanrequiredforhotorcoldforging.Bothretractableanddisposable
corescanusedtocreateholesandinternalpassages.Gasandshrinkageporosityare
182
substancereducedandmechanicalpropertiesareenhanced.Theprocesscanbeappliedto
bothferrousandnonferrousalloysandbothwroughtandcastalloybeprocessed.
An adaptation of the process can be used to produce metal matrix
compositesbyforcingthepressurizedliquidaroundformedorfiberreinforcedthathave
beenpositionedinthemold.Anothermodificationinvolvestheuseofthixotropicsemi
solidmaterial.Heretheneedtointroduceapreciseamountofmoltenmetalintothedieis
eliminatedbystartingwithchucksofmetalthathavebeenheatedintothesemisolid
range.Thixotropicmaterialcanbehandledmechanically,likeasolid,butshapedatlow
pressurebecauseitflowedlikealiquidwhenagitatedorsqueezed.Theabsenceofthe
turbulentflowminimizesthegaspickupandentrapment.Sincethematerialisalready
partiallysolid,solidificationshrinkageandrelatedporosityisreduced.Coolingwhile
underpressurecompletesthesolidification,whilesimultaneouslyproducinghighquality
intricatepartswithgoodfinishandprecision[20].
RULEOFTHEMIXTURE
Ruleofmixturesisamethodofapproachtoapproximateestimationofcomposite
materialproperties,basedonanassumptionthatacompositepropertyis thevolume
weightedaverageofthephases(matrixanddispersedphase)properties.Accordingtothe
RuleofMixturespropertiesofthecompositematerialareasfollows
a)Density:dc=(dm*Vm)+(dr*Vr)where,
Dc,dm,drdensitiesofthecomposite,matrixanddispersedphase
respectively;
Vm,Vrvolumefractionofthematrixanddispersedphaserespectively.
2) CoefficientofThermalExpansion:
CoefficientofThermalExpansion(CTE)inlongitudinaldirection(along
thefibers)
cl
=(m *Em *Vm + f*Ef*Vf)/(Em*Vm +Ef*Vf)
2
cl, m, f CTEofcompositeinlongitudinaldirection,matrixanddispersedphase
(fiber)
respectively;
Em,Efmodulusofelasticityofmatrixanddispersedphase(fiber)respectively.
Coefficient of Thermal Expansion (CTE) in transverse direction
(perpendiculartothefibers).
ct =(1+Pm)m *Vm + f *Vf
PmPoissonratioofmatrix.
Poissonsratio=Lateralstrain/Longitudinalstrain
3) Modulusofelasticity:
Modulusofelasticityinlongitudinaldirection(Ecl)
183
Ecl=Em*Vm+Ef*Vf
Modulusofelasticityintransversedirection(Ect)
1/Ect=Vm/Em+Vf/Ef
4) Tensilestrength:
Tensile strength of longfiber reinforced composite in longitudinal
direction.
c = m*Vm + f*Vf
Wherec,m,,fntensilestrengthofthecomposite,matrixanddispersed
phasefiberrespectively.
Tensilestrengthofshortfiberedcompositeinlongitudinaldirection(Fiber
lengthislessthancriticalvalueLx)
Lc=f*d/c
Where
dDiameterofthefiber;
cshearstrengthofthebondbetweenthematrixanddispersedphase(fiber).
c = m*Vm + f*Vf*(1Lc/2L)
WhereLLengthofthefiber.
3.5Machiningprocess
ForcompletetheManufacturingofcompositemetalmatrixmaterialstoinvolve
thedifferentmachiningprocesslikethatturning,milling,drillingetc.,Particlereinforced
aluminiummatrixcomposites(AMCs)arehighstrengthlightweightmaterialsconsisting
ofacomparativelysoftaluminiumalloyandhardembeddedceramicparticles.Thehigh
hardnessoftheparticlesresultsinexcellentabrasionresistance.However,thisproperty
lendspoormachinabilityinvolvinghightoolwearandsurfaceimperfectionsonthework
pieces.Forthisreason,CVDdiamondtippedindexableinsertswereusedforturning
AA2124with25%volumeproportionofSiCparticles.Thesurfaceintegrityisinfluenced
bythetoolgeometry,whichaffectsthestressconditionintheshearzone.Intheresearch
describedtheinfluenceofmodifiedcornergeometriesandthewidthofflankwearland
wereinvestigated.Theresultsshowedthatsurfaceroughnessvaluescanbedecreasedby
usingtoolswithwipergeometry.Anincreasingflankwearlandwidthoftheinsertsledto
areductionofthesurfaceimperfections[21].
Theinfluenceofcuttingconditions(cuttingvelocityandfeed)andcuttingtimeon
turning metal matrix composites (MMCs). A plan of experiments, based on the
techniquesofTaguchi,wasperformedmachiningwithcuttingconditionsprefixedin
184
workpieces.Anorthogonalarrayandtheanalysisofvariance(ANOVA)areemployedto
investigatethecuttingcharacteristicsofMMC(A356/20/SiCpT6)usingPCDcutting
tools.Theobjectivewastoestablishacorrelationbetweencuttingvelocity,feedandthe
cuttingtimewiththetoolwear,thepowerrequiredtoperformthemachiningoperation
andthesurfaceroughnessinworkpiece.Thesecorrelationswereobtainedbymultiple
linear regression. Finally, confirmation tests were performed to make a comparison
betweentheexperimentalresultsforeseenfromthementionedcorrelations[22].
Anexperimentalandnumericalstudyoftheevolutionofcuttingforces,toolwear
and surface finish, measured when drilling the particulate metal matrix composite
A356/20/SiCpT6 is presented. The experimental work was developed through the
continuous measurement of the cutting forces with an appropriate piezoelectric
dynamometer. The wear type was identified and its evolution with cutting time was
measured.Drillswithpolycrystallinediamondweretested.Thesurfacefinishoftheholes
wasevaluatedwithaprofilometer.
Usingtheexperimentalresults,anumericalsearchofoptimaldrillingconditionswas
performed.Sincetherearecontradictoryobjectives,suchasmaximizationoftoollifeand
minimizationoftoolwear,theconceptoftheParetooptimumsolutionisconsideredin
the optimization procedure. An evolution strategy is adopted to obtain the optimal
solutionforcuttingspeed,feedrateandtoollifepredictionwithindustrialinterest[23].
Thewidescaleintroductionofmetalmatrixcomposite
(MMCs)willincrease
simultaneouslywithdevelopmentintechnologies.Aluminium
matrixcompositesare
widely used for their favorable specific strength/stiffness and corrosion resistance
properties. As a consequence of the widening range of applications of MMCs, the
machiningofthesematerialshasbecomeaveryimportantsubjectforresearch.MMCs
are extremely difficult to machine (turning, milling, drilling, threading) due to their
extremeabrasiveproperties.WiththeprojectedwidespreadapplicationofMMCs,itis
necessary to develop an appropriate technology for their efficient and costeffective
machining.ThispaperdealswiththesurfaceintegrityofdrilledAl/17%SiCparticulate
MMCs.Drydrilling,tests,atdifferentspindlespeed,feedrates,drills,pointanglesof
drillandheattreatment,wereconductedinordertoinvestigatetheeffectofthevarious
cuttingparametersonthesurfacequalityandtheextentofthedeformationofdrilled
surfaceduetodrilling,.Forthisreason,thesurfaceroughnessoftheworkpiecematerial
wasinvestigatedafterdrilling,operations.Theworkpiecematerialwasdrilledinfour
heattreatmentconditions:asreceived,solutiontreated,andsolutiontreatedandagedfor
4and24h.Thedrillsusedwere5mmdiameter,and90,118and130pointangles.
Theexperimentswereperformedunderconditionsthedifferentspeedsof260and1330
rpmandthefeedratesof0.08and0.16mm/rev.drilling,testswerecarriedoutusing
highspeedsteel(HSS),TiNcoatedHSSandsolidcarbidedrills.Intheexperimental
results,itisdeterminedthatincreasingdrillhardnessandfeedratedecreasethesurface
roughness of drilled surface forall heat treated conditions. In addition, the optimum
surfaceroughnesswasdeterminedwhenthesolidcarbidedrilltoolswereusedonthe
specimenswithpackagedcondition[24].
185
Inthisstudy,wearbehaviorof
various toolsinmillingprocessof Al
4Cu/B4Cpcompositeswasinvestigated. Forthis purpose,compositesamples were
producedbyliquidphasesinteringtobeusedinmillingoperation.Fivedifferentcutting
speedsataconstantfeedrateof0.20mm/zwereusedinordertodeterminetheeffectof
cuttingspeedontoolwearandtoolwearmechanisminmillingofthesecomposites.
Millingoperationswerecontinueduntilflankwearlimit(VB)=0.3mmwasattainedfor
each tool. Flank wear was determined by using optical microscopy whereas wear
mechanismswereexaminedbyusingscanningelectronmicroscopy(SEM).Experimental
resultsbroughtoutthattriplecoatedtoolshowedthehighestwearresistanceatallcutting
speeds.Inadditionlowercuttingspeedsyieldedlowertoolwearforalltools[25].
Thequalityofthecomponents producedduringendmillingofAl/SiCparticulate
metalmatrixcomposites(PMMCs)isimportantasitinfluencestheperformanceofthe
finishedparttogreatextent.Hence,theestimationofsurfaceintegritycancatertothe
requirementsofperformanceevaluation.Therefore,anunderstandingofsurfaceintegrity
providesmanyopportunitiestoavoidfailuresenhancecomponentintegrityandreduce
overallcosts.Thispaperpresentstheresultsofanexperimentalresearchonendmilling
ofAl/SiCPMMC.Theaimoftheinvestigationistoenhancetheknowledgeaboutthe
machinability of Al alloy reinforced with SiC using TiAlN coated carbide end mill
cutters. Investigations on surface quality and the extent of subsurface damage of
machinedAl/SiCPMMCandAlalloywerecarriedoutatdifferentlevels ofcutting
conditions. The comparison of Al/SiC PMMC and Al alloy on the basis of surface
integrity(surfaceroughness,residualstress,microstructureandmicrohardness)wastried
out in order to know the machinability of two materials. The results show that the
presence of the reinforcement enhances the machinability in terms of both surface
roughness and lower tendency to clog the cutting tool, when compared to a non
reinforcedAlalloy.Theresultswouldservetounderstandtheendmillingmachining
processbetter;provideinputsthatcanensurebettermachiningofAl/SiCPMMCand
thusexpectedtoleadtechnologicalandeconomicalgainswiththeuseofAl/SiCPMMC
invariousindustrialapplicationsbyreplacingAlalloys[26].
4.0CONCLUSIONSANDFUTUREWORK
Inthepresentwork,themanufacturingandmachiningofMMCswereinvestigated.
Thefollowingresultswereobtained:
1. ThehistoryanddevelopmentofMMCswerediscussed.
2. ThecurrentliteratureofMMCsandtheAluminum,TitaniumandManganese
MMCsandtheirperformancewerestudied.
3. TheprocessflowanalysisofMMCsdividedintofourpartslikethatCAD/CAM,
Testing,Manufacturingandmachiningwasstudied.Inthisstudiedlearnaboutthe
variousmanufacturingandmachiningprocesses.
4. ThefutureworkisthecombinationofanyoneoftheAluminum,Titaniumand
ManganeseMMCsandusingsuitablemanufacturingprocessesandmachining
process.
186
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INTERNATIONALJOURNALOFMECHANICAL

parameters that control machinability characteristics are extrinsic parameters (cutting

Geometric modeling of conceptual design

Design testing and evaluation

Drafting and Documentation

NC Programming, Machining, Inspection and Assembly

=(m Em Vm + fEfVf)/(EmVm +EfVf)

17. J.P.Kaushish.Manufacturing processes, Prentice HallofIndia Pvt.Ltd(2008)

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