Microstrain behavior of metal-matrix composites.
Metal matrix composites compression microstrain behavior, analyzing continuous fiber composites of magnesium-boron and copper-tungsten
Hay, D. R.↗
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Additive manufacturing of metal matrix composites
Although Metal matrix composites (MMCs) are superior to most sought-after metallic alloys, their challenging fabricability has limited their widespread use in bulk-form applications. Among the many advanced fabrication techniques, Additive Manufacturing (AM), owing to its unique capabilities to produce near-net shapes, has drawn significant traction in the past two decades, especially for materials that are difficult to process using traditional methods. However, unlike pure metal/alloy systems, MMCs are highly sensitive to the processing conditions prevailing in AM techniques due to factors such as the high melting point of reinforcement particles and the potential for in-situ reactions. Therefore, it may be a while before metal matrix composites are commercially produced via AM. This review will discuss the current state-of-the-art design, fabricability, and performance of various additively manufactured MMCs. A particular focus will be on microstructural evolution and microstructure-property relationships. The most employed AM techniques, such as directed energy deposition, powder bed fusion, binder jetting, sheet lamination, and solid-state friction stir processing, are fundamentally different in terms of thermo-kinetics, forming the perspective for this review. A detailed comparison of microstructural evolution and process parameter optimization, including feedstock preparation methods and the role of machine learning and modeling among the different AM processes, is also presented. Finally, a critical evaluation of emerging AM technologies for MMCs is also provided, highlighting their potential advantages and challenges.
36 - MATERIALS SCIENCE↗
Program For Analysis Of Metal-Matrix Composites
METCAN (METal matrix Composite ANalyzer) is computer program used to simulate computationally nonlinear behavior of high-temperature metal-matrix composite structural components in specific applications, providing comprehensive analyses of thermal and mechanical performances. Written in FORTRAN 77.
Murthy, P. L. N.↗
METCAN: The metal matrix composite analyzer
Metal matrix composites (MMC) are the subject of intensive study and are receiving serious consideration for critical structural applications in advanced aerospace systems. MMC structural analysis and design methodologies are studied. Predicting the mechanical and thermal behavior and the structural response of components fabricated from MMC requires the use of a variety of mathematical models. These models relate stresses to applied forces, stress intensities at the tips of cracks to nominal stresses, buckling resistance to applied force, or vibration response to excitation forces. The extensive research in computational mechanics methods for predicting the nonlinear behavior of MMC are described. This research has culminated in the development of the METCAN (METal Matrix Composite ANalyzer) computer code.
Hopkins, Dale A.↗
Elastic properties of metal-matrix composites
Thin metal matrix composite rods elastic properties, examining Al-W system by Young and shear modulus measurements
Hay, D. R.↗
Considerations concerning fatigue life of metal matrix composites
Since metal matrix composites (MMC) are composed from two very distinct materials each having their own physical and mechanical properties, it is feasible that the fatigue resistance depends on the strength of the weaker constituent. Based on this assumption, isothermal fatigue lives of several MMC's were analyzed utilizing a fatigue life diagram approach. For each MMC, the fatigue life diagram was quantified using the mechanical properties of its constituents. The fatigue life regions controlled by fiber fracture and matrix were also quantitatively defined.
Radhakrishnan, V. M.↗
Development and fabrication of high strength alloy fibers for use in metal-metal matrix composites
Metal fiber reinforced superalloys are being considered for construction of critical components in turbine engines that operate at high temperature. The problems involved in fabricating refractory metal alloys into wire form in such a manner as to maximize their strength properties without developing excessive structural defects are described. The fundamental principles underlying the development of such alloy fibers are also briefly discussed. The progress made to date in developing tungsten, tantalum and columbium base alloys for fiber reinforcement is reported and future prospects for alloy fiber development considered.
King, G. W.↗
Method and apparatus for in situ synthesis of SiC, SiC ceramic matrix composites, and SiC metal matrix composites during additive manufacturing
Methods and apparatuses for in situ synthesis of SiC, CMCs, and MMCs are disclosed, comprising: providing an apparatus having: an electromagnetic energy source; an autofocusing scanner; a powder system for SiC and one or more powders; a powder delivery system; a shielding gas comprising argon and/or nitrogen; and a computer coupled to and configured to control the energy source, scanner, powder system, and powder delivery system to deposit layers of the sample; programming the computer with specifications of the sample; using the computer to control electromagnetic radiation, mixing ratio, and powder deposition parameters based on the specifications of the sample; and using the autofocusing scanner to focus and scan the electromagnetic radiation onto the sample while the powders are concurrently deposited by the powder delivery system onto the sample to create a melting pool to deposit one or more layers onto the sample. Other embodiments are described and claimed.
Liu, Jian↗
Metal-Matrix Composite Parts With Metal Inserts
Developmental fabrication process produces metal-matrix composite (MMC) parts with integral metal inserts. With inserts, MMC parts readily joined to similar parts by use of brazing, welding, or mechanical fasteners. Process conceived to make strong, lightweight components of structures erected in outer space. Also useful on Earth, in such automotive parts as rocker arms, cylinder liners, and pistons. Potential industrial applications include parts subjected to high stresses at high temperatures, as in power-generation, mining, and oil-drilling equipment.
Majkowski, T.↗
Real-Time Investigation of Solidification of Metal Matrix Composites
Casting of metal matrix composites can develop imperfections either as non- uniform distributions of the reinforcement phases or as outright defects such as porosity. The solidification process itself initiates these problems. To identify or rectify the problems, one must be able to detect and to study how they form. Until, recently this was only possible by experiments that employed transparent metal model organic materials with glass beads to simulate the reinforcing phases. Recent results obtained from a Space Shuttle experiment (using transparent materials) will be used to illustrate the fundamental physics that dictates the final distribution of agglomerates in a casting. We have further extended this real time investigation to aluminum alloys using X-ray microscopy. A variety of interface-particle interactions will be discussed and how they alter the final properties of the composite. A demonstration of how a solid-liquid interface is distorted by nearby voids or particles, particle pushing or engulfment by the interface, formations of wormholes, Aggregation of particles, and particle-induced segregation of alloying elements will be presented.
Kaukler, William↗
Fiber-metal matrix composites.
Fiber-metal matrix composites fabrication, applications, mechanical properties and powder metallurgy
Weeton, J. W.↗
Manufacturing Challenges Associated with the Use of Metal Matrix Composites in Aerospace Structures
Metal Matrix Composites (MMCs) consist of a metal alloy reinforced with ceramic particles or fibers. These materials possess a very high strength to weight ratio, good resistance to impact and wear, and a number of other properties which make them attractive for use in aerospace and defense applications. MMCs have found use in the space shuttle orbiter's structural tubing, the Hubble Space Telescope's antenna mast, control surfaces and propulsion systems for aircraft, and tank armors. The size of MMC components is severely limited by difficulties encountered in joining these materials using fusion welding. Melting of the material results in formation of an undesirable phase (formed when molten Aluminum reacts with the reinforcement) which leaves a strength depleted region along the joint line. Friction Stir Welding (FSW) is a relatively nascent solid state joining technique developed at The Welding Institute (TWI) in 1991. The process was first used at NASA to weld the super lightweight external tank for the Space Shuttle. Today FSW is used to join structural components of the Delta IV, Atlas V, and Falcon IX rockets as well as NASA's Orion Crew Exploration Vehicle and Space Launch System. A current focus of FSW research is to extend the process to new materials, such as MMCs, which are difficult to weld using conventional fusion techniques. Since Friction Stir Welding occurs below the melting point of the workpiece material, this deleterious phase is absent in FSW-ed MMC joints. FSW of MMCs is, however, plagued by rapid wear of the welding tool, a consequence of the large discrepancy in hardness between the steel tool and the reinforcement material. This chapter summarizes the challenges encountered when joining MMCs to themselves or to other materials in structures. Specific attention is paid to the influence of process variables in Friction Stir Welding on the wear process characterizes the effect of process parameters (spindle speed, traverse rate, and length of joint) on the wear process. A phenomenological model of the wear process was constructed based on the rotating plug model of Friction Stir Welding. The effectiveness of harder tool materials (such as Tungsten Carbide, high speed steel, and tools with diamond coatings) to combat abrasive wear is also explored. In-process force, torque, and vibration signals are analyzed to assess the feasibility of in situ monitoring of tool shape changes as a result of wear (an advancement which would eliminate the need for off-line evaluation of tool condition during joining). Monitoring, controlling, and reducing tool wear in FSW of MMCs is essential to implementation of these materials in structures (such as launch vehicles) where they would be of maximum benefit. The work presented here is extendable to machining of MMCs, where wear of the tool is also a limiting factor.
Prater, Tracie↗
Composite-Metal-Matrix Arc-Spray Process
Arc-spray "monotape" process automated, low in cost, and produces at high rate. Ideal for development of new metal-matrix composites. "Monotape" reproducible and of high quality. Process carried out in controlled gas environment with programmable matrix-deposition rates, resulting in significant cost saving
Westfall, Leonard J.↗
Fatigue damage criteria - Matrix, fibers and interfaces of continuous fiber reinforced metal matrix composites
Continuous fiber reinforced metal matrix composites (MMC) are projected for use in high temperature, stiffness critical parts that will be subjected to cyclic loadings. Depending on the relative fatigue behavior of the fiber and matrix, and the interface properties, the failure modes of MMC can be grouped into four catagories: (1) matrix dominated, (2) fiber dominated, (3) self-similar damage growth, and (4) fiber/matrix interfacial failures. These four types of damage are discussed and illustrated by examples. The emphasis is on the fatigue of unnotched laminates.
Johnson, W. S.↗
Experimental study of a metal-matrix composite
A metal-matrix specimen was investigated using moire interferometry with 2400 lines/m (60,960 l/in.). The specimen was a 6-ply (0/ + or - 45)s boron-aluminum tensile coupon with a central slot. The unequal deformations in fibers and matrix were evident. Special attention was given to a plastic slip zone in the matrix. Normal and shear strains were calculated in the slip zone; the shear-strain concentration factor rose dramatically with the onset of plastic slip and continued to rise gradually with load to 95 percent of the failure load. The precipitous change from maximum tensile strain in one fiber to zero tensile strain in the neighboring fiber was accommodated by the very high shear strains of the matrix in the slip zone. Experimental considerations are discussed: shear strains are independent of rigid-body rotations; simplified strain calculations are justified; averaging across the narrow slip region and the influence of finite thickness of the specimen grating contribute to underestimation of peak strains.
Post, D.↗
Metal-matrix composites: Status and prospects
Applications of metal matrix composites for air frames and jet engine components are discussed. The current state of the art in primary and secondary fabrication is presented. The present and projected costs were analyzed to determine the cost effectiveness of metal matrix composites. The various types of metal matrix composites and their characteristics are described.
Source record↗
METCAN simulation of candidate metal matrix composites for high temperature applications
The METCAN (Metal Matrix Composite Analyzer) computer code is used to simulate the nonlinear behavior of select metal matrix composites in order to assess their potential for high temperature structural applications. Material properties for seven composites are generated at a fiber volume ratio of 0.33 for two bonding conditions (a perfect bond and a weak interphase case) at various temperatures. A comparison of the two bonding conditions studied shows a general reduction in value of all properties (except CTE) for the weak interphase case from the perfect bond case. However, in the weak interphase case, the residual stresses that develop are considerably less than those that form in the perfect bond case. Results of the computational simulation indicate that among the metal matrix composites examined, SiC/NiAl is the best candidate for high temperature applications at the given fiber volume ratio.
Lee, Ho-Jun↗
The Application of Metal Matrix Composite Materials in Propulsion System Valves
Metal Matrix Composite (MMC) materials have been developed and used in many applications to reduce the weight of components where weight and deflection are the driving design requirement. MMC materials are being developed for use in some propulsion system components, such as turbo-pumps and thrust chambers. However, to date, no propulsion system valves have been developed that take advantage of the materials unique properties. The stiffness of MMC's could help keep valves light or improve life where deflection is the design constraint (such as seal and bearing locations). The low CTE of the materials might allow the designer to reduce tolerances and clearances producing better performance and lighter weight valves. Using unique manufacturing processes allow parts to be plated/coated for longer life and allow joining either by welding or threading/bolting. Additionally, casting of multi part pre-forms to form a single part can lead to designs that would be hard or impossible to manufacture with other methods. Therefore, NASA's Marshall Space Flight Center (MSFC) has developed and tested a prototype propulsion system valve that utilizes these materials to demonstrate these advantages. Through design and testing, this effort will determine the best use of these materials in valves designed to achieve the goal of a highly reliable and lightweight propulsion system. This paper is a continuation of the paper, The Application of Metal Matrix Composite Materials In Propulsion System Valves, presented at the JANNAF Conference held in April, 2002. Fabrication techniques employed, valve development, and valve test results will be discussed in this paper.
Laszar, John↗