International Journal of Research in Advanced Technology IJORAT

Vol 1, Issue 9, NOVEMBER 2016

Aluminium Based Metal Matrix Composites:

A Review Influence of Reinforced Particles;
Techniques; Factors Affecting the Composite
Dr.Ansari1 ,Mr.S.Sakthivel2 ,Dr.P.Murugesan3
Associate Professor, Mechanical Department, Francis Xavier Engineering College, Tirunelveli, India
Assistant Professor, Mechanical Department, Francis Xavier Engineering College, Tirunelveli, India
Associate Professor, Mechanical Department, Francis Xavier Engineering College, Tirunelveli, India
Abstract - The composite material is composed of a discrete reinforcement and distribution in a
continuous phase of matrix. In Aluminium based metal matrix composite are being used for a variety of
application such as military, electrical industries, aerospace and automotive purposes owing to their
improved properties such that high strength to weight ratio, high strength , high modulus and good duality
and excellent wear and correction resistance. There are wide variety of processes for processing the AMCs,
in this context manufacturing technology of metal matrix composites discussed.This paper presents the
influence of various reinforced particles and process parameters on the properties of Aluminium based metal
matrix composite through stir casting process.
Keywords: Stir casting, composite, processes, Aluminium metal matrix composite, Mechanical properties
Introduction
Metal matrix composite is refers to a composite
consist of metal or alloy, combined with metal or
non-metallic reinforcement. Metal matrix composite
is reinforced with Nano particles referred as a metal
matrix Nano composite. Aluminum is widely used a
matrix material due its high wear resistance,
corrosion resistance and high strength to weight
ratio.Addition of high modulus and high strength
refractory particle to the low ductile matrix produces
composite whose properties are inn between matrix
and reinforcement. In this properties are improved by
controlling the processing conditions, distribution of
reinforcement and relative amount.Manufacturing of
Aluminium metal matrix composites can be broadly
categorized into two groups one is liquid state
process which includes squeeze casting, ultrasonic
assisted casting, compo casting and stir casting, the
other category is solid state process, which includes
friction stir process, vapour deposition technique,
powder blending followed by consolidation and
diffusion bonding.
Implications of reinforced particles on aluminum
metal matrix composite

Jhony James et al. [8] prepared hybrid Aluminium

metal matrix composite reinforced silicon carbide
and titanium di boride. Authors also studied
machining and mechanical properties, morphology of
the composite and reinforced particle distribution by
optical microscopy. In this work % of reinforcement
has been fixed (10% SiC and 0-5% TiB2) to
maximum of 15 weight % to have high strength and
cost effective composite. Hardness test has been
carried out using Vickers hardness testing instrument
and it shows addition of reinforcement SiC and TiB 2
increases hardness value. But increase in
reinforcement up to 15 wt. % reveals reduction in
hardness value. Tensile test was carried out on the
tensile samples of different compositions. From
tensile test results it has been observed that addition
of reinforcement SiC to base metal added 20%
strength to the composite but addition of TiB2
reduction in 50-60% strength is recorded. From wear
test analysis proved that the addition of TiB 2
increased the wear resistance behavior of composite.
The effect of machining parameters like cutting speed
(s), feed rate (f), depth of cut (d) and weight
percentage of TiB2 on surface roughness were
investigated during turning operation.
Balasubramanian, Maheswaran [1]investigated the
mechanical resistance behavior of AA6063

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International Journal of Research in Advanced Technology IJORAT

Vol 1, Issue 9, NOVEMBER 2016

particulate composites with the inclusion of micronsized silicon carbide (SiC) particles with different
weight percentages in an AA6063 Aluminium matrix.
AA6063/SiC particulate composites containing
0,5,10 and 15 weight percent of SiC particles were
produced by stir casting. Standard mechanical tests
were conducted on the composite plates, and the
mechanical resistance to identification, tensile force
and sliding force are evaluated. It has been observed
that upon addition of SiC particles, the resistance
against indentation is increased and the resistance
against tensile force is initially increased and then
decreased. By using scanning electron microscopy
(SEM), the fracture appearance of the broken
specimen subjected to tensile force and
morphological changes in the surface subjected to
sliding force are analyzed.
M. Vamsi Krishna et al. [23]prepared Al6061-SiC &
Al6061-SiC/Graphite hybrid composites and
compared the mechanical properties. The composites
were prepared using stir casting method in which
amount of reinforcement is varied from 5-15% in
steps of 5wt%. The prepared composites are
characterized by microstructural studies and density,
and mechanical properties were evaluated as per the
standards. The microphotographs of the composites
revealed fairly uniform distribution of the particles in
composites with clustering at few places.
The dispersed Graphite and SiC in Al6061 alloy
contributed in enhancing the tensile strength of the
composites. The scanning electron micrographs of
the samples indicated uniform distribution of the
reinforcement particles in the matrix without any
voids.
Viney Kumar,Anthony.M.Xacior[24]investigated the
effect of rpm on specific wear rate and comparison of
mechanical properties of two metal matrix
composites. In first case Al6061, 4% Mg chosen as a
base material and varying composition of fly ash and
composition of fly ash varied from 10% to 20% in
steps of 5% taken as reinforcement.
In second case Al6061, 4% Mg, 4% Graphite was
taken as base material and composition of fly ash
varied from 10% to 20% in steps of 5%. It was found
that tensile strength increase with addition of fly ash.
Similarly when graphite was added then a decrease in
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tensile and hardness was observed. The composite

with 4%Mg, 15%Fly ash found to be maximum
tensile whereas composite of 4%Mg, 20%Fly ash
was found to be of maximum hardness. Specific wear
rate decreases with addition of fly ash up to a certain
volume whereas with graphite addition it also
decreases.
Pardeep Sharma et al.[16]focused on the effect of
graphite particles addition on the microstructure of
Al6082 metal matrix composites manufactured by
conventional stir casting process. The reinforcement
content was varied from 0% to 12% in a step of 3%.
The microstructures of the manufactured composites
were analyzed by scanning electron micrographic
test. Elemental mapping of the Al6082 and 12% Gr
reinforced composite was carried out to see the
different elements present with their amount.
Different elements present in the manufactured
composites were verified by X-ray diffraction
technique to justify the elemental map analysis.
K.R.Padmavathi,Dr.Ramakrishan[15]investigated
wear and friction behavior of Al6061 with various
percentage volumes of Multiwall carbon nanotube
and Silicon Carbide reinforcement through stir
casting method followed by die-casting. Wear test
was made by using pin on disc apparatus and found
that under mild wear conditions, the composite
displayed lower wear rate and friction coefficient
compared to Aluminium. Authors find severe wear
conditions, the composite displayed higher wear rate
and friction coefficient and it was clarified that the
friction and wear behavior of Al-SiC-MWCNT
composite is largely influenced by the applied load.
Also find the hardness of the composite was
increased by increasing the percent volume of
reinforcement.
S.Suresh, Shenbaga vinayaga moorthi [22]fabricated
Al-TiB2 metal matrix composite by using the in-situ
salt-metal reaction. With TiB2 as the particulate
addition the properties of Al6061 alloy can be greatly
improved & increases the strength of the Aluminium.
The wear resistance of this material is due to lack of
pull out of this material from the Aluminium matrix.
Also the material when machine with nonconventional methods like EDM will show better
machinability due to its high conductivity.

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Vol 1, Issue 9, NOVEMBER 2016

Kenneth kanayn alaneme, Olusola Joseph Ajayi

[10]Investigated the microstructure and mechanical
properties of Zn-27Al based composites reinforced
with rice husk ash(RHA),silicon carbide, graphite
particles. Authors observed the tensile strength and
yield strength decreased slightly with increase in the
weight ratio of RHA in the composite with a
maximum of 8.5% and 9.6% reduction respectively
observed for as much as 40% RHA(corresponding to
40% reduction in SiC)in the hybrid reinforcement.
Habibur Rahman, Mamum Al Rashed[5] prepared a
composite containing 0,5,10 and 20 wt. % of SiC
reinforcement in Aluminium matrix. Microstructural
observation
revealed
clustering
and
nonhomogeneous distribution of SiC particles in the Al
matrix. From the results showed thatintroducing SiC
reinforcement in aluminum (Al) matrix increased
hardness and tensile strength. Porosities were
observed in microstructures and increased with
increasing wt. % of SiC reinforcement in AMCs.
Siddesh Kumar NG et al.[19] developedA12219
reinforced with B4C&MoS2 for hybrid composites by
using stir casting technique.Authors observed the
density and micro hardness of A12219 alloy in
relatively low as compared to prepared hybrid
composites. Tensile strength is minimum for
A1229+3% B4C+5% MoS2 and maximum for
Al2219 alloy. In addition of B 4C and MoS2
reinforcement decreases the wear rate of hybrid
composite and increase the wear resistance of the
composites.
Mohan vanarotti et al. [13] studied the mechanical
properties and residual stress on A356-SiC metal
matrix composites by stir casting process. Authors
found that increase in SiC content from 5 to 15wt. %
in A356-SiC MMCs resulted an improvement of
46% and 15% in hardness and tensile properties
respectively.
S.G.Kulkarni et al. [11]observed that fly ash can be
successfully used along with alumina as hybrid
reinforcement. The composite fabricated by stir
casting Al356 alloy as a matrix material and
reinforcement used is 4,8,12 wt. % fly ash, 4,8,12 wt.
% alumina and combination of equal amount of fly
ash and alumina in 4,8,12 wt. %. Authors observed
fly ashes as reinforcement reduces the density of the
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composite as well as mechanical properties are

improved.
J.Jebeen moses et al. [9] prepared Aluminium alloy
AAl6061 reinforced with SiC particles by stir
casting and study the effect of SiC amount varied by
0,5,10 and 15 wt. %. Authors found that the
reinforcement of SiC particles is improved the micro
hardness and ultimate tensile strength of the AMCs.
Monoj singla et al.[14] developed Aluminium based
silicon carbide particulate metal matrix composite.
Aluminum (98.4% C.P) and SiC(320-grit) chosen for
the study. Reinforcement of SiC weight fraction was
5%, 10%,15%,25% and 30%, by keeping all other
parameters constant. Authors observed that uniform
dispersion of SiC particles in the Aluminium matrix
through the two step stir casting method, maximum
hardness and maximum impact strength obtained at
25% weight fraction of 320 grit size SiC particles.
Stir casting: In a stir casting process, the reinforcing
phases (usually in powder form) are distributed into
molten Aluminium by mechanical stirring. Stir
casting of metal matrix composites was initiated in
1968, when S.Ray introduced alumina particles into
Aluminum melt by stirring molten Aluminium alloy
containing the ceramic powders[17]. A typical stir
casting process of Aluminum alloy matrixcomposite
is illustrated in figure 1[12]. Mechanical stirring in
the furnace is a key element of this process.
The resultant molten alloy, with ceramic particles,
can then be used for die casting, permanent mold
casting, or sand casting. Stir casting is suitable for
manufacturing composite with up to 30% volume
fractions [12] of reinforcement. The cast composites
are sometimes further extruded to reduce porosity,
refine the microstructure, and homogenize the
distribution of reinforcement. A major concern
associated with the stir casting process is segregation
of reinforcing particles which is cost by surfacing or
settling of the reinforcement particles during the
melting and costing processes The final distribution
of the particles in the solid depends on the material
properties and process parameters such as the wetting
condition of the particles with the melt, strength of
mixing, relative density, and rate of solidification.
The distribution of the particles in the molten matrix
depends on the geometry of the mechanical stirrer,
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stirring parameters, placement of the mechanical

stirrer in the melt, melting temperature, and the
characteristics of the particles added[4,6].
An interesting recent development in stir casting is a
two-step mixing process. In this process, the matrix
material is heated to above its liquid us temperature
so that the metal is totally malted. The melt is then
cooled down to a temperature between the liquidus
and solidus points and kept in a semi-solid state. At
this stage, the pre heated particles are added and
mixed. The slurry is again heated to a fully liquid
state and mixed thoroughly.
Stir casting allows for the use of conventional metal
processing method with the addition of an
appropriate stirring such as mechanical stirring;
ultrasonic or electromagnetic stirring; or centrifugal
force stirring[18]. The major merit of stir casting is
its applicability to large quality production. Among
all the well-established metal matrix composite
fabrication methods, stir casting most economical
(compared to other methods). Stir casting costs as
little as one third to one tenth for mass production.
For that reason, stir casting is currently the most
popular commercial method of producing aluminum
based composite. Process of stir casting is shown in
figure1.
Compo casting: stir casting is one of the simplest
ways of producing Aluminium matrix composite.
However, it suffers from poor incorporation and
distribution of the reinforcement particles in the
matrix. These problems become especially significant
as there reinforcement size decrease due to greater
agglomeration tendency and reduced wettability of
the particles with the melt. Development of new
methods for addition of very fine particles to metallic
melts which would results in more uniform
distribution and effective incorporation of the
reinforcement particles into the matrix alloy is
therefore valuable compocasting is a liquid state
process in which that reinforcement particle are
added to a solidification melt while being vigorously
agitated. It has been shown that the primary solid
particles already formed in the semi-solid slurry can
mechanically entrap the reinforcing particles, prevent
there gravity segregation and reduce their
agglomeration [3,7]. These will result in better
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distribution of the reinforcement particles. The lower

porosity observed in the castings has been attributed
to the better wettability between the matrix and the
reinforcement particles as well as the lower volume
shrinkage of the matrix alloy.
Squeeze casting: Although the concept of squeeze
casting dates back to the 1800s[2,7], the first actual
squeeze casting experiment was not conducted until
1931[25]. Squeeze casting process is the combination
of gravity die casting and closed die forging. The
technique in which metal solidifies under pressure
within closed die halves. The applied pressure and
the instantaneous contact of molten metal with the
die surface produces rapid heat transfer that yields a
porous free casting with mechanical properties
approaching the wrought products.Squeeze casting
offers high metal yield, nil or minimum gas or
shrinkage porosity, excellent surface finish and low
operating costs.
Squeezecasting (also known as extraction casting,
squeeze forming and liquid forging) was developed
to produce high quality components. In this process,
pressure is applied on the solidification liquid metal.
Due to the intimate contact between the liquid metal
and mould and hence higher rate of heat removal
across the metal mold interface, premium quality
casting are obtained. The patent on this process
seems to be that of James Hollingrake in 1819 from
Manchester. The steps involved in squeeze casting
process are: (i) pouring of metered quality of liquid
metal with adequate super heat in to the die cavity,
(ii) application of pressure on the liquid metal and
maintaining the same till the solidification is
complete and (iii) removal of casting and preparation
of the die for the next cycle.
Powder Metallurgy: powder metallurgy is the
process of blending fine powdered materials, pressing
them into a desired shape (compacted), and then
heating the compressed material in a controlled
atmosphere to bond the material (sintering). The
powder metallurgy process generally consists of four
basic steps; (1) powder manufacture, (2) powder
mixing and blending, (3) compacting, (4) sintering.
Compacting is generally performed at room
temperature, and the elevated temperature process of

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sintering is usually conducting at atmospheric

pressure.

control of stirring speed and bottom pouring of the

mold.

Two main techniques used to form and consolidate

the powder are sintering and metal injection molding.
Recent developments have made it possible to use
rapid manufacturing techniques which use the metal
powder for the products. Because with this technique
the powder is melted and not sintered, better
mechanical strength can be accomplished.

Wettability
between
reinforcement alloy

Powder metallurgy is a highly evolved method of

manufacturing reliable net shaped components by
blending elemental or pre alloyed powders together,
compacting this blend in a die, and sintering or
heating the pressed part in a controlled atmosphere
furnaces to bond the particles metallurgically. The
P/M process is a unique part fabrication method that
is highly cost effective in producing simple or
complex parts at, or close to final dimensions.

matrix

metal

and

It can be defined as the ability of a liquid to spread on

a solid surface. Some of the reasons that contribute to
low wettability are increase in surface area as the size
of particles decreases, increasing tendency for
agglomeration of particles, surface energy etc.
Methods to improve wettability are coating of
particles, addition of alloying elements to the molten
matrix alloy, treatment of particles and ultrasonic
irradiation of the melt.
Porosity in cast metal matrix Nano composites
Porosity levels should be kept to minimum as this
kind of a composite defect can be detrimental to the
correction resistance of the casting and it can control
mechanical properties of the cast metal. It arises due
to gas entrapment during mixing, Hydrogen evolution
and shrinkage. Strategies to minimize porosity are
compo casting in vacuum, extensive inert gas
bubbling through the melt, casting under pressure,
compressing and extruding and rolling of materials
after casting to close the pores.
Chemical reaction between the cast matrix alloy
and reinforcement particles

Figure 2: Process of powder metallurgy

Factors affecting the composite fabrication by stir
casting
Factor affecting the preparation of Aluminium based
metal matrix composite are uniform distribution of
reinforcement materials, Wettabilitybetween the two
main substances,porosity in the cast metal matrix
Nano composite and chemical reactions between the
cast metal matrix alloy and reinforcement particles.
Uniform distribution of reinforcement materials
This problem arises due to the density differences
between reinforcement particles and matrix alloy
melt. Factors such as type of stirrer used melt
temperature, type amount and nature of particles etc.
It can be solved by proper design of the stirrer,
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It contributes to the poor quality of cast AMC.

Preheating of both matrix reinforcement before
mechanical stirring can solve the problem. The
surface of both must be property cleaned in order
minimize the reaction between the two.
Process parameters
Stirring speed
It is an important parameter because it improves
wettability and stirring while slurry is solidifying
improves incorporation of particles into matrix alloy.

Stirring temperature
It influences change in viscosity of Al matrix and
also accelerates chemical reaction between matrix
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Vol 1, Issue 9, NOVEMBER 2016

and reinforcement material. The viscosity of liquid

decreased with increasing processing temperature
with increasing holding time.
3.
Reinforcement preheat temperature
Preheating of reinforcement particles assisted in
removing surface impurities, desorption of gases and
altering the surface composition.
Stirring time (holding time)
It distributes particles in the matrix and creates
perfect interface bond between and reinforcement.
Particles are distributed uniformly when holding time
is less.

4.

During stirring vortex created, it can suck air

bubbles into liquid metal at higher temperature with
the more stirring time it is possible from particles
clusters in the composite.
Preheated temperature of the mould
In order to improve the mechanical properties of cast
composite, it is better to have preheated permanent
mould for pouring the slurry which in turn helps to
remove the entrapped gases from the mould.
5.
Power feed rate
Feed rate of powders particles must be uniform
otherwise it promotes clustering of particles which in
turn causes the porosity and inclusion defects.
Discussions
1.

2.

6.
Tensile test results has been the
observed that addition of reinforcement
SiC to base metal added 20% strength
to the composite but addition of TiB2
reduction in 50-60% strength is
recorded. From wear analysis proved
that TiB2 particles increase thewear
resistance behavior.
The vichkers harness value of the
composite increase with additional
inclusion of SiC particles, with an
increase of approximately 50% upon
addition of 10% SiC Particles.The
tensile strength increase with increasing

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7.

SiC inclusion up to 10% SiC with

decrease in ductility and then decrease
for 15% SiC inclusion.
The tensile strength of SiC & SiC /Gr
reinforced
hybrid
particulate
Aluminium composite with different
weight fraction was studied and the
maximum tensile strength observed is
192.45 Mpa at 15wt.% of SiC /Gr. And
the mechanical behavior of SiC /Gr
reinforced hybrid composite showed
improved results when compared with
single reinforcement.
Specific area rate decrease up to 1500
rpm in sample Al6061, 10%, fly ash and
4% graphite and sample Al6061,15%
fly ash, 4% graphite. This is due to
lubricant behavior of graphite as rpm
increases due to heat generated by high
speed graphite diffuses which makes the
composite more ductile and specific
wear rate increase with increase of rpm
in sample Al6061 20%, fly ash 4%
graphite. This is due to excess amount
of fly ash which makes material so
brittle.
Aluminium reinforced with SiC and
MWCNT better dry abrasive wear
resistance and for all values of the
applied load, specific wear rate decrease
with the increase of the % of MWCNT.
And the hardness of the composite
increase as the hybrid ratio increases.
Fly ash as a reinforcement reduces the
density of composite material as well as
mechanical properties are improved.
Compressive strength of Al356 alloy
and fly ash composite is increased.
The fly ash along with other
reinforcement like alumina improves
the
mechanical
properties
like
compressive strength in large amount
keeping densities low.

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