Metal matrix composite


A metal matrix composite is composite material with at least two constituent parts, one being a metal necessarily, the other material may be a different metal or another material, such as a ceramic or organic compound. When at least three materials are present, it is called a hybrid composite. An MMC is complementary to a cermet.

Composition

MMCs are made by dispersing a reinforcing material into a metal matrix. The reinforcement surface can be coated to prevent a chemical reaction with the matrix. For example, carbon fibers are commonly used in aluminium matrix to synthesize composites showing low density and high strength. However, carbon reacts with aluminium to generate a brittle and water-soluble compound Al4C3 on the surface of the fiber. To prevent this reaction, the carbon fibers are coated with nickel or titanium boride.

Matrix

The matrix is the monolithic material into which the reinforcement is embedded, and is completely continuous. This means that there is a path through the matrix to any point in the material, unlike two materials sandwiched together. In structural applications, the matrix is usually a lighter metal such as aluminum, magnesium, or titanium, and provides a compliant support for the reinforcement. In high-temperature applications, cobalt and cobalt–nickel alloy matrices are common.

Reinforcement

The reinforcement material is embedded into a matrix. The reinforcement does not always serve a purely structural task, but is also used to change physical properties such as wear resistance, friction coefficient, or thermal conductivity. The reinforcement can be either continuous or discontinuous. Discontinuous MMCs can be isotropic and can be worked with standard metalworking techniques, such as extrusion, forging, or rolling. In addition, they may be machined using conventional techniques, but commonly would need the use of polycrystalline diamond tooling.
Continuous reinforcement uses monofilament wires or fibers such as carbon fiber or silicon carbide. Because the fibers are embedded into the matrix in a certain direction, the result is an anisotropic structure in which the alignment of the material affects its strength. One of the first MMCs used boron filament as reinforcement. Discontinuous reinforcement uses "whiskers", short fibers, or particles. The most common reinforcing materials in this category are alumina and silicon carbide.

Manufacturing and forming methods

MMC manufacturing can be broken into three types—solid, liquid, and vapor.

Solid state methods

MMCs are fabricated at elevated temperatures, which is an essential condition for diffusion bonding of the fiber/matrix interface. Later on, when they are cooled down to the ambient temperature, residual stresses are generated in the composite due to the mismatch between the coefficients of the metal matrix and fiber. The manufacturing RS significantly influence the mechanical behavior of the MMCs in all loading conditions. In some cases, thermal RS are high enough to initiate plastic deformation within the matrix during the manufacturing process.

Applications

MMCs are nearly always more expensive than the more conventional materials they are replacing. As a result, they are found where improved properties and performance can justify the added cost. Today these applications are found most often in aircraft components, space systems and high-end or "boutique" sports equipment. The scope of applications will certainly increase as manufacturing costs are reduced.
In comparison with conventional polymer matrix composites, MMCs are resistant to fire, can operate in wider range of temperatures, do not absorb moisture, have better electrical and thermal conductivity, are resistant to radiation damage, and do not display outgassing. On the other hand, MMCs tend to be more expensive, the fiber-reinforced materials may be difficult to fabricate, and the available experience in use is limited.