Particle reinforced metal matrix composites are now being produced commerically, and in this paper the current status of these materials is reviewed. The different types of reinforcement being used, together with the alternative processing methods, are discussed. Depending on the initial processing method, different factors have to be taken into consideration to produce a high quality billet. With powder metallurgy processing, the composition of the matrix and the type of reinforcement are independent of one another. However, in molten metal processing they are intimately linked in terms of the different reactivities which occur between reinforcement and matrix in the molten state. The factors controlling the distribution of reinforcement are also dependent on the initial processing method. Secondary fabrication methods, such as extrusion and rolling, are essential in processing composites produced by powder metallurgy, since they are required to consolidate the composite fully. Other methods, suc...

Particle reinforced aluminium and magnesium matrix composites

A fixed grid numerical modelling methodology for convection-diffusion mushy region phase-change problems

The physical and mechanical properties that can be obtained with metal matrix composites (MMCs) have made them attractive candidate materials for aerospace, automotive and numerous other applications. More recently, particulate reinforced MMCs have attracted considerable attention as a result of their relatively low costs and characteristic isotropic properties. Reinforcement materials include carbides, nitrides and oxides. In an effort to optimize the structure and properties of particulate reinforced MMCs various processing techniques have evolved over the last 20 years. The processing methods utilized to manufacture particulate reinforced MMCs can be grouped depending on the temperature of the metallic matrix during processing. Accordingly, the processes can be classified into three categories: (a) liquid phase processes, (b) solid state processes, and (c) two phase (solid-liquid) processes. Regarding physical properties, strengthening in metal matrix composites has been related to dislocations of a very high density in the matrix originating from differential thermal contraction, geometrical constraints and plastic deformation during processing.

Particulate reinforced metal matrix composites — a review

The flow of homogeneous fluids through porous media: analogies with other physical problems

During dendritic solidification of castings and ingots, a number of processes take place simultaneously within the semisolid region. These include crystallization, solute redistribution, ripening, interdendritic fluid flow, and solid movement. The dendritic structure which forms is greatly affected by convection during the early stages of solidification. In the limit of vigorous convection and slow cooling, grains become spheroidal. Alloys with this microstructure possess rheological properties in the semisolid state which are quite different from those of dendritic alloys. They behave thixotropically, and viscosity can be varied over a wide range, depending on processing conditions. The metal structure and its rheological properties are retained after solidification and partial remelting. The semisolid alloys can be formed in new ways, broadly termed «semisolid metal (SSM) forming processes». Some of these are now employed commercially to produce metal components and are also used to produce metal-matrix composites

Behavior of metal alloys in the semisolid state

Rheological behavior of Sn-15 pct Pb alloy in the solidification range has been investigated using a Couette type viscometer. In samples partially solidified before shearing, deformation is localized and primarily intergranular. Samples containing more than about 0.15 fraction solid exhibit an “apparent yield point” which is on the order of 106 dyne per sq cm and increases with increasing fraction solid. When shearing is conducted continuously while the alloy is cooled from above the liquidus to the desired final fraction solid, shear stresses required for flow are reduced by about three orders of magnitude. The solid-liquid mixture now behaves as a fluid slurry. Structural examination shows that shear takes place throughout the cross section of the specimen and that the solid is present as a fine grained particulate suspension. Flow behavior can be described by a viscosity which depends on fraction solid, decreases with increasing shear rate and exhibits hysteresis when shear rate is changed. For shear rates of 200 sec−1, at 0.40 fraction solid, viscosity is about 5 poise which is equivalent to that of heavy machine oil at room temperature. The fact that the slurry is highly fluid at large fractions solid suggests potential applications in new and existing metal casting processes.

Rheological behavior of Sn-15 pct Pb in the crystallization range

An analysis is given of interdendritic flow behavior during solidification of castings and ingots, assuming resistance to flow is as in other types of porous media. Driving forces for the flow are solidification contractions and gravity acting on a fluid of variable density. Detailed flow calculations are given for horizontal, unidirectional, steady-state solidification, using aluminum-copper alloys as examples. Conditions are quantitatively described under which gravity induced convection becomes an important contributory cause of macrosegregation. A critical condition of flow is shown to produce local melting with resulting formation of “channel-type” segregates. Qualitative examples are given of application of the ideas presented to interpretation of macrosegregation in commercial ingots, with specific reference to centerline segregation and “channel-type” segregation, including “V” segregates, “A” segregates and “freckles”.

Interdendritic fluid flow and macrosegregation; influence of gravity

A new process for the preparation and casting of metal-particulate non-metal composites is described. Particulate composites of ceramic oxides and carbides and an Al-5 pet Si-2 pct Fe matrix were successfully prepared. From 10 to 30 wt pct of A12O3, SiC, and up to 21 wt pct glass particles, ranging in size from 14 to 340 ώ were uniformly distributed in the liquid matrix of a 0.4 to 0.45 fraction solid slurry of the alloy. Initially, the non-wetted ceramic particles are mechanically entrapped, dispersed and prevented from settling, floating, or agglomerating by the fact that the alloy is already partially solid. With increasing mixing times, after addition, interaction between the ceramic particles and the liquid matrix promotes bonding. Efforts to mix the non-wetted particles into the liquid alloy above its liquidus temperature were unsuccessful. The composite can then be cast either when the metal alloy is partially solid or after reheating to above the liquidus temperature of the alloy. End-chilled plates and cylindrical slugs of the composites were sand cast from above the liquidus temperature of the alloy. The cylindrical slugs were again reheated and used as starting material for die casting. Some of the reheated composites possessed “thixotropy.” Distribution of the ceramic particles in the alloy matrix was uniform in all the castings except for some settling of the coarse, 340ώ in size, particles in the end-chilled cast plates.

Preparation and casting of metal-particulate non-metal composites

A metal composition characterized by degenerate dendritic or nodular primary discrete solid particles suspended in a secondary phase having a lower melting point than the primary particles and which secondary phase can be solid or liquid. The method involves raising the temperature of a metal alloy to a value at which the alloy is largely or completely in the molten state. The melt then is subjected to vigorous agitation and the temperature is reduced to increase the portion of the mixture in solid degenerate dendrite or nodular form up to about sixty-five percent, but usually up to about fifty percent, while continuing the agitation. At this juncture the temperature of the liquid-solid composition can be reduced to cause solidification thereof or it can be cast. The solidified composition can be stored and later it can be brought again to the liquid-solid mixture state and then recast.

Composition and methods for preparing liquid-solid alloys for casting and casting methods employing the liquid-solid alloys

This invention provides a composite composition comprising a metallic matrix having a concentration of third phase solid particles homogeneously dispersed throughout the metallic matrix. The metallic matrix can be liquid, solid or partially solid and can have (a) a dendritic structure or (b) up to 65 weight percent of a structure comprising degenerate dendritic or nodular primary discrete solid particles suspended in a secondary phase having a lower melting point than the primary particles which secondary phase can be solid or liquid. The third phase particles can be metallic, non-metallic or a combination metallic-nonmetallic compositions and have a surface composition which is not wet by the metallic matrix when the matrix is a liquid.

R. Mehrabian

Papers

Rheological behavior of Sn-15 pct Pb in the crystallization range

Interdendritic fluid flow and macrosegregation; influence of gravity

Preparation and casting of metal-particulate non-metal composites

Composition and methods for preparing liquid-solid alloys for casting and casting methods employing the liquid-solid alloys

Metal composition and methods for preparing liquid-solid alloy metal composition and for casting the metal compositions