This schematic diagram indicates some of the extensive range of possible composite materials.  Composites can be broadly divided into:

• Ceramic Matrix Composites (CMC)
• Metal Matrix Composites (MMC)
• Natural materials
• Polymer Matrix Composites (PMC)

Key Texts

1. B Cantor, F Dunne and I Stone - Metal and ceramic matrix composites, Institute of Physics, Bristol, c2004. ISBN 0-7503-0872-9.
2. ST Mileiko - Metal and ceramic based composites, Elsevier, Amsterdam & Oxford, 1997. ISBN 0-444-82814-1.
3. MR Winstone, A Partridge and JW Brooks - The contribution of advanced high-temperature materials to future aero-engines, Proceedings of the Institution of Mechanical Engineers - Part L: Journal of Materials: Design & Applications, 2001, 215(2), p63-73.

CERAMIC MATRIX COMPOSITES

Carbon-carbon composites [Kelly]

Carbon fibre preform

1. impregnated with char yielding organic liquid followed by pyrolysis:
   

   phenolic or furfuryl resins, yielding ~55% carbon at 1000°C
   liquid pitch and high isostatic pressure (70 MPa) yields ~85% carbon

2. chemical vapour deposition (CVD) of carbon from hydrocarbon precursor gas.
   

   methane or natural gas under isothermal, thermal gradient or differential pressure conditions

   Reference

   • A Kelly, Concise Encyclopaedia of Composite Materials, Pergamon Press, Oxford, 1989.  ISBN 0-08-034718-5.  UOP Library

   Further reading

   1. KK Chawla - Ceramic matrix composites, Chapman & Hall, London, 1993. ISBN 0-412-36740-8.
   2. ER Generazio - Advanced ceramic matrix composites: design approaches, testing, and life prediction methods, Technomic, 1996. ISBN 1-566-76334-7.
   3. Roger Naslain and Bryan Harris - Ceramic matrix composites: components, preparation, microstructure and properties, Elsevier Applied Science, London, 1989. ISBN 1-85166-460-2.
   4. R Warren - Ceramic-matrix composites, Blackie, 1992. ISBN 0-216-92682-3.
   5. SV Nair and K Jakus - High temperature mechanical behavior of ceramic composites, Butterworth-Heinemann, Oxford, 1995. ISBN 0-7506-9399-1.
   6. AR Boccaccini, C Kaya and KK Chawla - Use of electrophoretic deposition in the processing of fibre reinforced ceramic and glass matrix composites: a review, Composites Part A: Applied Science and Manufacturing, 2001, 32(8), 997-1006.
   7. Zhihong Zheng and Dorel Feldman, Synthetic fibre-reinforced concrete, Progress in Polymer Science, 1995, 20(2), 185-210.

METAL MATRIX COMPOSITES

FABRICATION PROCESSES

LIQUID STATE: The generation of a metal matrix composite is primarily achieved by means of a liquid-metal technique:  either infiltration of a molten metal into fibre bundles or preforms or the mixing of molten metal with reinforcement particles.  The processing occurs at high temperatures with the risk of chemical reactions.

Liquid pressure forming (LPF), including the Cray process [Ponzi]
Similar to RTM with molten metal fed into an evacuated fibre-filled mould from below by pressure.  Gases and volatile binders are vented from the mould top.  Pressures are higher (10-15 atm for Saffil preforms, 70 atm for 50 v/o carbon fibre).  High clamping loads, massive dies for heat retention, long solidification times.

Pressure infiltration casting (PIC), including PCAST process [Ponzi]
Similar to LPF except the mould is a cold thin walled vessel located inside and clamped by a pressure vessel.   Low cost tooling.

Squeeze casting [Ponzi]
High-quality casting by pressurising to 1000-2000 atm during solidification collapsing porosity and increasing thermal contact with unheated die wall resulting in rapid solidification rate.  High capital facility and tooling costs.

Casting/semi-slurry technique [Ponzi]
Two phase process for (continuous) casting, limited to short-fibre/particulate reinforcement.  Phase 1: dispersal of reinforcement in molten metal.  Phase 2: shear dilution.  Produces ingots which can be subsequently reprocessed.

Osprey technique [Ponzi]
Liquid aluminium alloy atomised, and fed with 5μm (silicon carbide) particles, in nitrogen atmosphere sprayed onto collector surface.

SOLID STATE

Low temperature processes with diffusion bonding.

Foil techniques [Ponzi]
Compaction of fibre reinforcement within metal foil matrix below the solidus temperature.  Some interfacial reaction occurs.  Typical forms include:

• foil plating by cold rolling
• explosion welding
• hot pressing (HP)
• hot isostatic pressing (HIP)

Powder techniques [Ponzi]
Aluminium alloy matrix materials canned and vacuum-degasses prior to consolidation to minimise surface oxidation and contamination

SECONDARY PROCESSING

Extrusion, forging, rolling, stamping, superplastic forming.

Machining [Taya & Arsenault]:

• superhard cutting and grinding tools
• AJM:  abrasive waterjet cutting
• CHM:  chemical milling
• EBM:  electron beam machining
• EDM:  electro-discharge machining
• LBM:  laser beam machining
• PAM:  plasma arc machining
• USM:  ultrasonic machining

Resource

• Metal Matrix Composites database (National Composites Network)

Further reading

1. N Chawla and KK Chawla - Metal Matrix Composites, Springer, 2006. ISBN 0-387-23306-7.
2. TW Clyne and PJ Withers - Introduction to metal matrix composites, Cambridge University Press, 1993. ISBN 0-521-41808-9.
3. JN Fridlyander - Metal matrix composites, Chapman & Hall, London, 1995. ISBN 0-412-58260-0.
4. KA Lucas and H Clarke - Corrosion of aluminium-based metal matrix composites, Wiley Research Studies Press, 1993. ISBN 0-471-94189-1.
5. KU Kainer - Metal matrix composites: custom-made materials for automotive and aerospace engineering, Wiley-VCH, Weinheim, c2006. ISBN 3-527-31360-5.
6. AG Metcalfe - Composite materials volume 1, Interfaces in metal matrix composites, Academic Press, New York & London, 1974. ISBN 0-12-136501-8.
7. C Ponzi, Metal matrix composite fabrication processes for high performance aerospace structures, Composites Manufacturing, 1992, 3(1) 32-42.
8. WJ Renton - Hybrid and Select Metal Matrix Composites, American Institute of Aeronautics and Astronautics (AIAA), New York, 1977.
9. Pradeep Rohatgi - Microstructure formation during solidification of metal matrix composites, TMS, USA, 1993. ISBN 0-873392-14-0.
10. JE Schoutens and K Tempo - Introduction to metal matrix composite materials, Metal Matrix Composites Information Analysis Center, 1982. ISBN 0-6864-8246-8.
11. M Taya and RJ Arsenault - Metal matrix composites: thermomechanical behavior, Pergamon Press, 1989. ISBN 0-08-036983-9.
12. Brian Terry and Glyn Jones - Metal-matrix composites: current developments and future trends in industrial research and applications, Elsevier Advanced Technology, 1990. ISBN 1-85617-021-7.

NATURAL MATERIALS

This topic is embedded throughout the module.  Key pages include:

• bio-based and biodegradable resins
• biomimetics
• natural fibres
• natural polymers (cellulose, chitin/chitosan,  proteins)
• sustainable composites
• wood-based composites and panel products

POLYMER MATRIX COMPOSITES

This topic is the core interest of this module.  The teaching support materials can be accessed from the MATS 324 home page.

In tonnage terms, rubbers and elastomers are important matrix materials.  They find application in tyres, hoses, conveyor belts, sonar domes, etc.  Initially these material systems were reinforced with cotton then rayon or nylon and latterly either steel or aramid, most often as cord reinforcement.

Further reading:

1. John Loadman, Tears of the tree: the story of rubber-a modern marvel, Oxford University Press, Oxford & New York, c2005. ISBN 0198568401. UOP Library.
2. D Boast and VA Coveney, Finite element analysis of elastomers, Professional Engineering Publications, Bury St Edmunds, 1999. ISBN 1860581714. UOP Library.
3. WC Wake and DB Wootton, Textile reinforcement of elastomers, Applied Science Publishers, London, c1982. ISBN 0-85334-998-3. UOP Library.