50 Years of Foundry Produced Metal Matrix Composites and Future Opportunities

This article introduces the paper '50 Years of Foundry Produced Metal Matrix Composites and Future Opportunities' published by '2019 AFS Proceedings of the 123rd Metalcasting Congress'.

1. Overview:

• Title: 50 Years of Foundry Produced Metal Matrix Composites and Future Opportunities
• Author: Pradeep Rohatgi, Ajay Kumar P., David Weiss
• Publication Year: 2019
• Publishing Journal/Academic Society: 2019 AFS Proceedings of the 123rd Metalcasting Congress
• Keywords: Metal matrix composites, mechanical properties, castings, foam, automotives

2. Abstracts or Introduction

3. Research Background:

Background of the Research Topic:

There is an increasing demand for lightweight, high-performance and recyclable materials in most all applications. Metal Matrix Composites (MMCs) are engineered materials and provide one of the best alternative solutions. MMCS have already replaced several conventional materials and are being used in aerospace, automotive and defense industries. Metal Matrix Composites, in general, consist of continuous or discontinuous fibers, whiskers, or particulates dispersed in a metallic alloy matrix. These reinforcements provide the composite with properties not achievable in monolithic alloys.

Status of Existing Research:

According to Global MMC Market Report 2019, there has been a linear growth of MMC production. MMC production volume has increased from 5 million kilograms to 7 million kilograms after 2012 and revenue has increased from 228.8 USD Million to 400 USD Million (Fig. 1). In 2004, 3.5 Million kilograms of MMCs were used and the number is increasing with an annual growth rate of more than 6%. Paper publications on MMCs have been increased exponentially as shown in Fig. 2. Cast metal matrix composites are widely manufactured in the foundry industry. The initial discovery on the synthesis of cast metal matrix composites was made by Badia and Rohatgi in 1965 at the Merica Laboratory of the International Nickel Company. Since the initial work in 1965, considerable progress has been made in the field of cast metal matrix composites.

Necessity of the Research:

Al-Si alloy and ductile cast iron have limitations in the volume percentages of the two phases and restricted to narrow ranges predicted by their phase diagrams. The morphology and spatial arrangement of reinforcements cannot be varied as freely as in synthetically produced composites. This paper reviews the historical perspective of cast metal matrix composites and discusses the property motivation for using metal matrix composites and discusses the components, which are currently being developed or are already being used. the future research imperatives and possibilities in cast metal matrix composites are also presented.

4. Research Purpose and Research Questions:

Research Purpose:

This paper aims to review the progress in Cast Metal Matrix Composites (MMCs) over the past 50 years, starting from the 1969 AFS paper by Badia and Rohatgi. It explores the property motivation, current applications, industry growth, and future directions of foundry-produced MMCs. The study also discusses various types of cast MMCs and their manufacturing processes.

Key Research:

The key research areas explored in this paper include:

• Historical development of cast MMCs since 1965.
• Property motivations and applications of cast MMCs in various industries.
• Different types of cast MMCs, such as aluminum-graphite, aluminum-silicon carbide, aluminum-alumina, and aluminum-fly ash composites.
• Current and future directions in cast MMC research, including nano-composites, functionally gradient materials, syntactic foams, self-healing, and self-lubricating composites.
• Solidification processing of metal composites, including stir casting, squeeze casting, rheocasting, and melt infiltration.
• Cost-effectiveness and manufacturing techniques for foundry-produced MMCs.

Research Hypotheses:

This paper is a review paper and does not explicitly state research hypotheses. However, implicitly, it can be inferred that the paper operates under the premise that:

• Cast Metal Matrix Composites have seen significant advancements and diversification in the 50 years since their initial development.
• Foundry production methods offer viable and cost-effective routes for manufacturing MMCs for various applications.
• Future research and development in cast MMCs hold substantial potential for creating advanced materials with tailored properties.

5. Research Methodology

Research Design:

This paper is a review paper that adopts a historical and descriptive research design. It surveys and synthesizes existing literature, research findings, and industrial applications related to foundry-produced metal matrix composites over the past 50 years.

Data Collection Method:

The data collection method involves reviewing and compiling information from:

• Academic publications and research papers related to cast metal matrix composites.
• Industry reports and market analyses on MMC production and applications.
• Patents and technical documents related to MMC manufacturing processes.
• Case studies and examples of MMC applications in automotive, aerospace, and other sectors.

Analysis Method:

The analysis method is primarily qualitative and involves:

• Historical analysis of the development timeline of cast MMCs, identifying key milestones and advancements.
• Descriptive analysis of different types of cast MMCs, their properties, manufacturing methods, and applications.
• Comparative analysis of different casting techniques for MMC production.
• Trend analysis of MMC market growth and future research directions.

Research Subjects and Scope:

The research subjects are foundry-produced Metal Matrix Composites (MMCs). The scope of the review encompasses:

• Cast MMCs produced using various foundry techniques like stir casting, squeeze casting, rheocasting, and melt infiltration.
• Different types of matrix materials (e.g., aluminum, magnesium, copper) and reinforcements (e.g., graphite, silicon carbide, alumina, fly ash).
• Applications of cast MMCs in automotive, aerospace, electronics, and other industries.
• Research and development efforts in cast MMCs from 1965 to 2018.

6. Main Research Results:

Key Research Results:

• The paper highlights the significant progress in cast MMC technology over the past 50 years, starting from the initial work on aluminum-graphite composites.
• It demonstrates the growth of the MMC market and the increasing number of publications in the field, indicating growing interest and research activity.
• Various foundry techniques, particularly stir casting, squeeze casting, and infiltration processes, have been developed and refined for MMC production.
• A wide range of cast MMCs have been developed using different matrix materials (Al, Mg, Cu, etc.) and reinforcements (graphite, SiC, Al2O3, etc.), tailored for specific applications.
• Applications of cast MMCs have expanded across diverse sectors, including automotive (pistons, cylinder liners, brake rotors), aerospace (structural tubes, electronic packaging), and recreational equipment.
• Recent research focuses on advanced cast MMCs, such as nanocomposites, syntactic foams, self-lubricating, and self-healing composites, to further enhance performance and functionality.
• Cost-effective production methods using low-cost reinforcements like fly ash and waste sand are being explored.

Analysis of presented data:

• Figure 1 illustrates the Global MMC market review for 2019, showing a linear growth in both volume and revenue from 2012 to 2019.
• Figure 2 shows the exponential increase in the number of papers published on Cast MMCs from 1988 to 2018, indicating the expanding research interest in the field.
• Figure 5 presents a cost comparison of different MMC types and reinforcement methods, highlighting the cost-effectiveness of liquid metal processes like stir casting compared to powder metallurgy and diffusion bonding.
• Table 1 provides a comprehensive list of selected matrix-dispersoid combinations used to make cast metal matrix composites, showcasing the diversity of materials and compositions.
• Table 2 lists selected landmarks in the development of cast metal matrix composites from 1965 to 2018, outlining key research contributions and organizations involved.
• Table 3 lists MMC uses in different sectors, demonstrating the wide range of applications in space, automotive, aerospace, thermal management, and recreation.
• Table 4 provides a list of MMC manufacturers and their applications in the automotive industry, indicating the industrial relevance of cast MMCs.
• Table 5 offers a comparative analysis of cylinder sleeve materials, rating Al-SiC-Graphite composites highly for various performance criteria.

Figure Name List:

• Figure 1. Global MMC market review 2019.3
• Figure 2. Number of papers on Cast MMCs published from 1988 to 2018.3
• Figure 3. The phase diagram restricted metal composites (a) Al-Si alloy and (b) Ductile cast iron.2
• Figure 4. Classification of metal matrix composites depending on size, arrangement, and shape of the reinforcement.
• Figure 5. Cost and type of reinforcements used in MMCs.2
• Figure 6. Injection of nickel-coated graphite in molten aluminum alloys in an initial experiment on casting aluminum-graphite particle composites by Rohatgi. (Merica Laboratory, International Nickel Company, 1965).6
• Figure 7. Injection of nickel-coated graphite in molten aluminum alloys in an initial experiment on casting aluminum-graphite particle composites by Badia. (Merica Laboratory, International Nickel Company, 1965).6
• Figure 8. Dispersion of graphite particles in an Al-9.2Si-4.7Ni-base.6
• Figure 9. (a) Aluminum-graphite piston (b) Aluminum-graphite liners used in Alpha Romeo and Ferrari automobiles in Formula One races (c) Aluminum graphite connecting rod (d) aluminum graphite liner die cast in place, in a small engine (e) centrifugally cast aluminum-graphite liner (f) Liner in from picture (e) in a small engine block.2
• Figure 10. Schematic views of the stir casting process.
• Figure 11. (a) microstructure of Al-Si/Saffil Fiber (b) A356/SiC composites (c) Al-Si/20 vol% spherical Al2O3p (d) Silicon carbide particle reinforced aluminum composite (e-f) Al-Si/20vol%.-graphite particle composite.2
• Figure 12. SEM micrographs of as-cast composites: (a, b) Al6061-9 wt%. TiB2.
• Figure 13. The rheoformed cylindrical part of 7075 aluminum matrix composite reinforced with nano-sized SiC particles.60
• Figure 14. Schematic of the casting experimental set-up used by X.Li. 57
• Figure 15. (a) A high magnification SEM image from Mg-TiC nanocomposites (b) Microhardness measurements with varying amount of TiC in the matrix.
• Figure 16. Schematic of the solidification nano processing method. The nanoparticles were first ultrasonic pre-processed with molten salt at room temperature and then incorporated into molten Al assisted by molten salt and mechanical stir 57.
• Figure 17. Experimental setup of salt assisted nanoparticle incorporation (a) and melt pressing using a hydraulic press (b).
• Figure 18. Schematic of the experimental methods.
• Figure 19. SEM images of the WC nanoparticle dispersion in Zinc. 54
• Figure 20. SEM micrograph of carbon short fibers used (a) uncoated (b) Ni-P coated (c) Picture an as-cast sample (d) Distribution of uncoated CSFs in composite C3 samples (e) Distribution of coated CSFS in composite CE3 samples (f) SEM micrograph of an agglomerated fiber region in sample CE3.54
• Figure 21. Formation of the composite during non-isothermal infiltration of a fiber preform by liquid metal.
• Figure 22. Schematic of Advanced Pressure Infiltration Casting (APICTM) Process. 68
• Figure 23. Physical and mechanical properties of composites as compared with the two most commonly used alloy, i.e. steel and aluminum.
• Figure 24. Comparison of specific properties of aluminum and magnesium matrix composites indicating the increase of stiffness and strength with respect to the matrix.
• Figure 25. MMC uses in automotive applications as cylinder liners, brake rotors, intake and exhaust valves, and driveshaft etc.
• Figure 26. A359/20 vol% SiCp composite brake rotor for an electric vehicle.
• Figure 27. Al-SiC composites as heat-spreader plates of an electronics cooling device for the world's first hybrid vehicle, the Prius.
• Figure 28. MMC crankshaft pulley made by infiltration of SIALON preform with aluminum.
• Figure 29. REL AI-MMC for (a) brake drum, (b) motorcycle brake rotor, and (c) automotive rotor.
• Figure 30. Al-SiC Graphite piston cylinder made by Eck Industries.
• Figure 31. MMC uses in space industries.
• Figure 32. Discontinuously reinforced aluminum MMCs for electronic packaging applications: (a-top) SiCp/Al electronic package for a remote power controller (photo courtesy of Lockheed Martin Corporation), and (b-bottom) cast Grp/Al components (photo courtesy of MMCC, Inc.).
• Figure 33 Train rotor made from Duralcan.
• Figure 34. Montage of lead-free copper- graphite composite castings.
• Figure 35. A356-10vol%SiC-4vol%Gr composite components.
• Figure 36 (a) Microstructure of A356-10vol% fly ash composite (b) Intake manifold made of Al-10% fly ash.
• Figure 37. Foam material created by introducing gas in Al-SiC melt.
• Figure 38. (a) Fly Ash -Cenospheres, (b) Fly Ash Cenospheres (Hollow) in a-Al Matrix (c) Al- foam Aluminum-fly ash Cenosphere syntactic foam (micrograph inset) within a steel frame (d). (Courtesy of Bob Purgert.)

7. Conclusion:

Summary of Key Findings:

This paper concludes that cast metal matrix composites have evolved significantly over the last 50 years, becoming a substantial industry. Despite barriers like cost and machining difficulties, MMCs offer enhanced properties and are utilized in various components across automotive, aerospace, and other sectors. Aluminum matrix composites, including those with silicon carbide, alumina, graphite, and fly ash, are prominent. Foundry techniques like stir casting and infiltration are key to MMC production. Current research is advancing nanocomposites, syntactic foams, and self-functional composites, promising further growth in MMC applications.

Academic Significance of the Study:

This review paper provides a comprehensive historical overview of cast metal matrix composites, consolidating 50 years of research and development. It highlights the evolution of MMC materials, processing techniques, and applications, offering valuable insights for researchers and experts in materials science, manufacturing, and metallurgy. The paper also identifies key research trends and future directions, contributing to the academic understanding of MMC technology.

Practical Implications:

The practical implications of this study are significant for industries seeking lightweight, high-performance materials. The paper showcases the viability of foundry-produced MMCs for various applications, particularly in automotive and aerospace engineering. It emphasizes the cost-effectiveness of certain MMC production methods and the potential for using low-cost reinforcements. The review encourages further adoption of cast MMCs in industrial applications by addressing manufacturing techniques, material selection, and future research opportunities.

Limitations of the Study and Areas for Future Research:

As a review paper, this study is limited by the scope of the reviewed literature. The paper points towards future research directions including:

• Preventing agglomeration of reinforcements in MMCs.
• Achieving uniform reinforcement distribution and strong interfacial bonding.
• Reducing MMC production costs through low-cost materials and processes.
• Simplifying the machining of MMCs.
• Developing comprehensive property databases for MMC component design.
• Establishing robust supply chains and manufacturing capabilities for large-scale MMC production.
• Creating recycling pathways for end-of-life MMC components.
• Developing smart MMC materials with self-healing and self-lubricating functionalities.
• Long-term performance testing of MMC components in diverse applications.
• Exploring ultrahigh-performance MMCs with graphene and carbon nanotube reinforcements.

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9. Copyright:

• This material is "Pradeep Rohatgi, Ajay Kumar P., David Weiss"'s paper: Based on "50 Years of Foundry Produced Metal Matrix Composites and Future Opportunities".
• Paper Source: https://doi.org/

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