List all available fabrication technique for MMC fabrications.

Describe in details 2
types of technique including their advantages and disadvantages.
A simple classification of metal matrix composite fabrication methods
i.

Solid state fabrication techniques.

Powder metallurgy
Diffusion bonding

ii.

Liquid state fabrication techniques.

Stir casting.
Rheocasting
Squeeze casting
Liquid-metal Infiltration

iii.

Vapor State processes

Co-spray Deposition.
Vapor Deposition.

iv.

In situ fabrication techniques

Describe in details 2 types of technique including their advantages and disadvantages.

i.

Diffusion Bonding

Diffusion Bonding is a solid state fabrication method, in which a matrix in form of

foils and a dispersed phase in form of long fibers are stacked in a particular order and
then pressed at elevated temperature.

The finished laminate composite material has a multilayer structure.

Diffusion Bonding is used for fabrication of simple shape parts (plates, tubes).

Layers of metal foil are sandwiched with long fibers, and then pressed through to
form a matrix

Example of Matrix : Aluminium alloy and Titanium

Example of Reinforcement: filament nitrate steel, silicon carbide and monofilament

boron.

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Figure below show the process of diffusion bonding technique :

Figure 1 :

Process of diffusion bonding technique

Step 1 : Apply aluminium foil

Step 2 : Cut to shape
Step 3 : Lay-up desired piles.
Fiber layer of Boron and aluminium foil is stacked stacked to produce
the desired fiber volume fraction.
Step 4 : Vacuum encapsulate
Binder form from resin is used to maintain the position.
Step 5 : Heat to fabrication temperature.
Combination of heat and pressure will be causing the matrix flow around
the fiber and form the bond with the matrix that nearest with matrix
layer.
Step 6 : Apply pressure and hold for consolidation cycle.
The metal matrix covers and holds the fiber.
Step 7 : Cool, remove and clean part
Advantages
Disadvantages
The process has the ability to produce This process is expensive and limited for
high quality joints so that neither

simple shape such as tube and plat.

metallurgical discontinuities nor porosity Great care is required in the surface

exist across the interface.
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preparation stage. Excessive oxidation or

 Diffusion bonding is free from ultraviolet

contamination of the faying surfaces

radiation and gas emission so there is no

would

direct

drastically.

detrimental

effect

on

the

decrease

the

joint

strength

environment, and health and safety

standards are maintained.
ii.

Powder Metallurgy
Powder metallurgy is a process by which fine powdered materials are blended,
pressed into a desired shape, and then heated to bond surfaces.
Typically used when large amounts of small, intricate parts with high precision are
required.
Little material waste and unusual mixtures can be utilized.
The component are simply mixed and then pressed and sinter.
Four basic steps:
i.

Powder manufacture.
Properties of powder metallurgy products are highly dependent on the
characteristics of starting powders.
Some important properties and characteristics are chemistry and purity,
particle size, size distribution, particle shape and Surface texture.
Useful in producing pre alloyed powders
Each powder particle can have the desired alloy composition.

ii.

Mixing or blending.
The majority of powders are mixed with other powders, binders, and
lubricants to achieve the desired characteristics in the finished product
Sufficient diffusion must occur during sintering to ensure a uniform
chemistry and structure.

iii.

Compacting.
The powder compaction or pressing is done in a mold.
The process can be done emphasis uniaxial or isostatic (cold isostatic press,
CIP or hot isostatic pressing, HIP).
The results of compaction (uniaxial and cold isostatic): green body

iv.

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Sintering

 The sintering process is performed to increase the strength of these

components which is through the establishment of a bond between the
powders by high temperature diffusion.
Sintering is conducted at a temperature of around 80% of the absolute
melting temperature of the matrix metal in the furnace.
Components that have been produced from HIP does not need to
sintered.
In the sintering operation, the pressed-powder compacts are heated in a
controlled atmosphere to right below the melting point.

Advantages

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Disadvantages

 Elimination or reduction of machining

Inferior strength properties

High production rates

High tooling costs

Complex shapes

High material cost

Wide variations in compositions

Size and shape limitations

Wide property variations

Dimensional changes during sintering

Scrap is eliminated or reduced

Density variations
Health and safety hazards

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