Metal Matrix Composites (MMCs)

Properties, Applications & Machining

Olivier Beffort

EMPA, Swiss Federal Laboratories for Materials Research and Testing

Dept. Materials Technology
Feuerwerkerstrasse 39
CH-3602 Thun
olivier.beffort@empa.ch
www.empathun.ch

6. Internationales IWF-Kolloquium
18/19.04.2002, Egerkingen, CH
 structure of the talk

introduction to MMCs

typical properties of MMCs

applications of MMCs

machining of MMCs

outlook - trends in R&D, market forecasts

 ca. 1975

sources: NASA & AFRL

Space Shuttle - main cargo bay struts

material: MMC - 6061/B/50f
total weight saving: 145 kg (-44% vs Al)
materials costs: > 1000 US-$ / kg
 ca. 1999

source: VW
VW-Lupo (Tdi) - rear brake drums
material: MMC - A359/SiC/20p
weight of drum: 1.55 kg
materials costs: < 5 US-$ / kg
 MMCs - materials with tailored properties ...

... by combination of metals and ceramics

specific properties of metals and ceramics

metals......... toughness
Al electrical & thermal conductivity
Mg heat resistance, "environmental stability"
(Ti) processability

ceramics..... Youngs Modulus, hardness, wear resistance

SiC strength
Al2O3 low coefficient of thermal expansion
C, B4C (shape of ceramic: fibres, particles)
 Types of reinforcement for MMCs
particles and "foams"

particles (ceramics, carbon, ...) "foams" (ceramics, graphite, ...)

volume fraction: 5 - 75% cearmic volume fraction: 20 - 90%
size: 0.1 - 500 m pore size: 50 nm - 1 mm
 Types of reinforcement for MMCs
fibres

100 Pm

short fibres (ceramics, carbon, ...) cont. fibres (ceramics, carbon, ...)
volume fraction: 10 - 30% volume fraction: 40 - 70%
size: : 1 - 6 m, L: 10-500 m size: : 6-150 m, L:
 structure of the talk

introduction to MMCs

typical properties of MMCs

applications of MMCs

machining of MMCs

outlook - trends in R&D, market forecasts

 particle reinforced MMCs

(PRM) vp: 5-75 %

isotropic properties
high wear resistance
low density ............................................... 2.6 - 3.1 g/cm3
high elastic modulus ............................... 90 - 300 GPa
high strength ............................................ 300 - 1000 MPa
good thermal conductivity ...................... 120 - 200 W/mK
low coeff. of thermal expansion (CTE) ... 7 - 20 10-6/K
 fibre reinforced MMCs

(FRM) vf: 10-70 %

anisotropic properties
low density ........................ 1.8 - 3.2 g/cm3
high strength ..................... 500 - 2000 MPa
high elastic modulus ....... 120 300 GPa
low CTE ............................. 0 - 10 10-6/K
elevated temperature resistance (strength, fatigue, creep)
 structure of the talk

introduction to MMCs

typical properties of MMCs

applications of MMCs

machining of MMCs

outlook - trends in R&D, market forecasts

 MMC brake discs & drums applications

MMC - type: AlSiMg/SiC/20-30p

trains (ICE) source:
Knorr Bremse
VW Lupo
Toyota RAV-4EV
Plymouth Prowler
GM EV-1, Precept, Impact
Ford Prodigy
Lotus Elise (1st series)
race carts (various)
....

source: Lotus Cars Ltd.

automotive applications - engine

Toyota Celica

source: Kolbenschmidt

source: Honda

cylinder blocks and pistons

(local reinforcement for wear and creep resist.)
material: AlSi + short fibres and/or particles
Porsche 911, Boxster
Toyota Celica
Honda Prelude, NSX, ...?
power conversion / electr. packaging applications
IGBT-modules (Insulated Gate Bipolar Transistor)

"thermal management applications"

50 mm
MMC - type:
AlSi/SiC/70p
CTE: 7-9 10-6/K

max rated voltage: VCE = 3300 V

Nominal current IC = 1200 A

source: EUPEC
 structure of an IGBT-module

Bond Wire
CTE [ppm/K]
Solder
Si Si Si 4.2
Copper
Al2O3 or AlN Insulation 6.7 / 4.4

Grease Cu or Al Heats Spreader 17 / 23.5

Heat
Cooler 17 / 23.5

source: ABB Semiconductors

 further MMC applications:

racing, sports, leisure

cylinder liners, push rods, brake calipers, ...
spikes for racing shoes & tires, golf clubs, bicycle frames, ....
aerospace applications
Space Shuttle - main cargo bay struts
Boeing 777 / Pratt & Whitney - fan exit guide vanes
Eurocopter - blade sleeves
F16 - ventral fins, fuel access door covers
thermal and electric transportation
heat sinks, electronic packaging, ....
cooking ware
power transmission cables (electric conductors)
robotics, linear technology, weaving machines, ........
military applications, .....
structure of the talk

introduction to MMCs

typical properties of MMCs

applications of MMCs in transportation

machining of MMCs

outlook - trends in R&D, market forecasts

frequent statements concerning MMC machining

MMC cannot be machined.................................... no !

conventional tools cannot be used for MMCs.... yes !

diamond tools are a must for MMC machining... yes !

MMCs cannot be machined cost effectively........ no !

MMCs are difficult to machine............................. yes !

 why are MMCs difficult to machine ?

because of the relative hardness of the reinforcing materials

 tool wear mechanisms occuring during
MMC machining

abrasion due to hardness of reinforcement

impact fatigue, break-outs

 tools suitable for MMC machining

PCD or CVD diamond tools are the best

do not use CBN tools

do not use HSS tools (not even coated ones)

do not use un-coated WC/Co tools

 influence of tool material on tool wear
0.6

PKD, vc 500 m/min

0.5
WC/TiN, vc 150 m/min
flank wear vB, [mm]

0.4

0.3

MMC material: Al/Al2O3/20p

0.2 vc: 500 m/min
feed: 0.4 mm/rev
0.1 DOC: 1.5 mm
operation: turning
0
0 2 4 6 8 10 12 14

time, [min]

source: Duralcan machining guidelines

 parameters affecting machinability

machining performance or machinability is

defined in terms of tool life, material removal rate
or surface quality of machined part

the influencing parameters are :

MMC material - particle type, vol. fract, temper, ...

tool - type and grade
machining parameters - feed, speed, DOC
 influence of MMC - reinforcement

the following characteristics decrease tool life:

increasing particle volume fraction

increasing particle size

increasing particle hardness

increasing aspect ratio of particles

influence of MMC - quality & temper

the following characteristics decrease tool life:

defects (porosity, inclusions, segregations, ...)

age hardening (peak aged condition T6)

 influence of tool - type and grade

controversy - PCD or CVD diamond ???

for PCD tools, influence of diamond grain size:

three common PCD grades: 2, 10 and 25 Pm
25 Pm best wear resistance; for roughing
2 Pm best edge quality for finishing
roughing and finishing operations

for roughing coarse grained PCD (or CVD)

and the most possible aggressive feed rate
and depth of cut are recommended: best
tool life performance

for finishing fine grained PCD or CVD and

moderate feed rate and depth of cut are
recommended: best surface finish quality
 influence of machining parameters

the following characteristics increase tool life:

high feed rate (< 0,5 mm/rev)

high depth of cut (< 5 mm)

medium cutting speed (300-500 m/min)

 influence of feed rate on material removal
MMC material: Duralcan F3S.20S
10000 tool material: PCD
9000 vc : 300m/min
volume removed (MMC), [cm3]

DOC: 0.5 mm
8000
operation: turning (stop @ 0.25 vB mm)
7000

6000

5000

4000

3000

2000

1000

0
0,1 0,2 0,4
feed rate, [mm/rev]

source: Duralcan machining guidelines

 machining operations

turning feasible, PCD or CVD diamond tools

milling feasible, PCD or CVD diamond tools
drilling difficult, PCD or CVD diamond tools
tapping critical, CVD tools in development stage
tap forming is an alternative to tap cutting

sawing feasible, WC- or PCD tipped blades

grinding feasible, diamond grinding
 MMC machining cost issues - example

US-study concerning machining costs of brake rotors

PCD - tools cast iron rotor MMC rotor

parts per day: 1900 3131
tool costs, $/day 402 2048
cost savings reference 0.15 $/rotor
CVD - tools
tool costs, $/day 568.75
MMC drilling cost issues - sp3 examples

Ford Motors Co.

drilling 6.8 mm diam. holes 1.00 deep into Al/SiC/20p
drilling conditions: speed:1350 rpm, feed: 0.0075 ipr
WC/Co-drills: 1 - 2 holes per drill $9 - $18 /hole
CVD-drills: 330 holes per drill $0.40 /hole

MSE
drilling 0.25 diam. holes into Al/SiC/20-48p
WC/Co-drills: < 1 hole per drill
CVD-drills: >200 holes per drill $0.52 /hole
(cost of CVD drill: $115/drill
 machining - conclusions

recommended machining
guidelines should be respected
only diamond tools should be
used for machining MMCs
an MMC with an ultrafine and low hardness
reinforcement is preferred
except tapping, most common machining
operations are possible
structure of the talk

introduction to MMCs

typical properties of MMCs

applications of MMCs in transportation

machining of MMCs

outlook - trends in R&D, market forecasts

materials and process development - future
materials development
selectively reinforced structures
functional, adaptive materials
graded materials
process technology
"reactive" in-situ generation of MMCs
near net shape MMC processing technologies
low cost MMC processing technologies
machining
adapted tools (materials, coatings, geometries, ...) and lubricants
optimised machining parameters
alternative machining processes
 MMC market forecasts 1999-2004

3500 market share: 62.2 %

3400
market share: 70.3 % 1999
AAGR: + 16.3 %
3000
2004
annual MMC world market, [t]

2500

2000
1999: 2.5 Mio kg, 103 Mio US-$
2004: 4.9 Mio kg, 173 Mio US-$
market share: 26.5 %
1600 market share: 21.9 %
1500
AAGR: + 9.8 %

1000 1000
market share: 5.4 % market share: 5.9 %
668 market share: 3.3 % market share: 4.5 %
500 AAGR: + 3.3 % AAGR: + 7.7 %

137 161 152 220

0
ground thermal aerospace / industrial /
transportation management defense recreational equip.

source: BCC, USA

 http://www.empathun.ch

http://mmc-assess.tuwien.ac.at