Dr.

Adepu Kumar
Professor
Department of Mechanical Engineering
National Institute of Technology, Warangal-506004
E-Mail: adepu_kumar7@[Link]
Contact No. : 9492783067
 Research Students:
 Research Area : FSW/FSP and EDM
1. [Link] - Friction stir processing of Aluminum based
surface composites (Awarded in oct. 2014)
2. [Link] Raju –Friction stir processing of copper based surface
composites ( Awarded in sept. 2014)
3. Dr. [Link] -Powder mixed EDM of Titanium Alloy
( Awarded in April 2014)
4. [Link] Gadahk _ Analytical Modeling of Friction stir welding
5. ( Awarded in 2016)
6. Dr. K. Murahari - Effect of surfactant concentration on EDM of
Titanium Alloy ( Awarded in 2016)
7. Mr. P. Naresh - Preparation and Characterization of Nano surface
composites using Friction stir processing ( Thesis Submitted)
8. [Link] - Dissimilar welding of Maraging steel and AISI 4130
steel ( Thesis Submitted)
9. [Link] Kumar - Modeling of Friction stir welding using Deform
Overview
 Need in Advances in Manufacturing Technology
 Preparation of Composite materials
1. Stir casting
2. Solid state welding process
3. Friction welding
4. Friction stir welding process
Need in Advances in Manufacturing
Technology
 Customer demand
 Development of New Materials
 Applications
 For example: Aluminum alloys are extensively
used in defense and aerospace applications
 Materials
 Composite material: A material that is made from
several different substances
 Metal matrix composite: composed of metal and other
parts(ceramic or organic compounds)
 Ceramic: a composite of ceramic and metallic materials
 Dental composite: a substance used to fill cavities in
teeth
 Alloy: A mixture of a metal and another element
 Mixture: The combination of several different
substances without chemical reaction.
Composite materials
 Composition materials or shortened to composites:
 Composite materials are materials made from two or
more constituent materials with significantly different
physical or chemical properties, that when combined,
produce a material with characteristics different from
the individual components.
 Metal Matrix Composite
 It is a mixture of matrix material and reinforcement.

 Up to 30% volume of reinforcement can be added to

the Matrix material.

 The reinforcement particles such as Al2O3, SiC, TiB2,

Gr, B4C etc. are generally used for making the
composite
 A metal matrix composite (MMC) is composite
material with at least two constituent parts, one being
a metal. The other material may be a different metal or
another material, such as a ceramic or organic
compound.

 When at least three materials are present, it is called a

hybrid composite.

 An MMC is complementary to a cermet.

 MMC’s are made by dispersing a reinforcing material

into a metal matrix.
 Matrix: The matrix is the monolithic material into
which the reinforcement is embedded, and is
completely continuous.

 Reinforcement: The reinforcement material is

embedded into the matrix. The reinforcement does
not always serve a purely structural task (reinforcing
the compound), but is also used to change physical
properties such as wear resistance, friction coefficient,
or thermal conductivity
Manufacturing methods
 MMC manufacturing can be broken into three types:
 Solid state method,

 Liquid state method, and

 Vapour deposition .
Solid state methods
 Powder blending and consolidation (powder
metallurgy): Powdered metal and discontinuous
reinforcement are mixed and then bonded through a
process of compaction, degassing, and thermo-
mechanical treatment (possibly via hot isostatic
pressing (HIP) or extrusion).
 Foil diffusion bonding: Layers of metal foil are
sandwiched with long fibers, and then pressed
through to form a matrix.
Liquid state methods
 Electroplating / Electroforming: A solution containing
metal ions loaded with reinforcing particles is co-deposited
forming a composite material.
 Stir casting: Discontinuous reinforcement is stirred into
molten metal, which is allowed to solidify.
 Squeeze casting: Molten metal is injected into a form with
fibers preplaced inside it.
 Spray deposition: Molten metal is sprayed onto a
continuous fiber substrate.
 Reactive processing: A chemical reaction occurs, with one
of the reactants forming the matrix and the other the
reinforcement.
 Vapour deposition
 Physical vapor deposition: The fiber is passed through a
thick cloud of vaporized metal, coating it.
 In situ fabrication technique
 Controlled unidirectional solidification of a eutectic
alloy can result in a two-phase microstructure with one
of the phases, present in lamellar or fiber form,
distributed in the matrix.
Applications
 Carbide drills are often made from a tough cobalt
matrix with hard tungsten carbide particles inside.
 Some tank armors may be made from metal matrix
composites, probably steel reinforced with boron
nitride
 Some automotive disc brakes use MMCs.
 driveshaft upgrade, cylinder liners, engine's cylinder
sleeves,
 landing gear in air crafts.
 electronics for its very high thermal conductivity.
Various methods of producing
MMC
 Stir casting
 Gel Casting
 Squeeze casting
 Friction stir processing
 Stir Casting
 Stir Casting is a liquid state method of composite
materials fabrication, in which a dispersed phase
(ceramic particles, short fibers) is mixed with a molten
matrix metal by means of mechanical stirring.
 Stir casting of metal matrix composites was initiated
in 1968, when S. Ray introduced alumina particles
into an aluminum melt by stirring molten aluminum
alloys containing the ceramic powders .

 Stir casting is suitable for manufacturing composites

with up to 30 % volume fractions of reinforcement.
Stir Casting Machine
Schematic diagram of stir cast set – up
Mixing of matrix and reinforment in stir
casting
 One – Step mixing process.
 Two – Step mixing process.
One – Step mixing process

 In this process, the matrix material is heated to

above its liquids temperature so that the metal is
totally melted. Add reinforcement to the molten
metal and mixed thoroughly. Mixed slurry is
poured in the mould and allowed to solidify to
form a composite.
 Two – Step mixing process
An interesting recent development in stir casting is a two – step
mixing process.

 In this process, the mixing is heated to above its liquids

temperature so that the metal is totally melted.

 The metal is then cooled down to a temperature between the

liquids and solidus points and kept in a semi - solid state.

Continue…
 At this stage, the preheated particles are added and

mixed.

 The slurry is again heated to a fully liquid state and

mixed thoroughly.

The effectiveness of this two – step processing method is

mainly attributed to its ability to break the gas layer
around the particle surface.
 Content of dispersed phase is limited ( not more
than 30 vol.%).
 Distribution of dispersed phase throughout the
mixing is not perfectly homogeneous:
 There are local clouds (clusters) of the dispersed particles
(fibers);
 There may be gravity segregation of the dispersed phase due
to a difference in the densities of the dispersed and matrix
phase.
Continue….

 A metered amount of matrix alloy was charged into the stainless

steel crucible or graphite crucible in a furnace under argon
atmosphere.

 The furnace temperature was raised according to the melting

temperature of matrix and held at the temperature until the
matrix material melted completely.

 A four blade stirrer can be used to stir the melt. Pairs of

calibrated chromel – alumel thermocouples were used to
measure and control the temperature of the furnace by
inserting into the melt and placing it close to the crucible wall.
 The stirring was started using the four blade stirrer, driven by a

variable speed motor, thus creating the vortex in the melt.

 After the formation of the vortex in the melt region,

reinforcement particles were added at uniform rates ( which

were previously preheated to a certain temperature separately

to enhance wettability separately).

 It was also ensured that temperature of the reinforcement

particles was as same as melt temperature to maintain uniform

viscosity of melt.

Cont…
 After the addition of the reinforcement particles,
the temperature of furnace was maintained at that
temperature and stirring was continued for a
specified time.
 The stirrer speed slurry was poured onto specially
designed mould with four rectangular plates and
one square plate tightened with the help of nuts
and bolts for easy separation of casting block from
mould and this mould is transferred to furnace – 1
for mechanical squeezing action using the
reciprocating action
 This reciprocating action helped in removing entrapped
gases. The melt was then left squeezed under pressure.

 The crucible with pressurized melt was immediately taken

out of furnace – 1 and water quenched. The quenching
ensured better uniformity in the distribution of the
reinforcement particles throughout the casting.

 The MMC billet was removed from mould by unscrewing

the plates.
Factors affecting successful fabrication of AMC
 In preparing metal matrix composites by the stir casting method, there
are several factors that need considerable attention, including
1. Stirring speed, stirring temperature, stirring time
2. Preheat temperature of the reinforcement particles, mould
temperature
3. The difficulty of achieving a uniform distribution of the reinforcement
material:
4. Wettability between the two main substances.
5. Porosity in the cast metal matrix composites.
6. Chemical reactions between the reinforcement materials and the
matrix alloy.
1. Stirring speed, stirring temperature, stirring
time
Stirring speed
 Mechanical stirring is necessary to help in promoting wettability.

 Stirring in a fully liquid condition does not help to incorporate particles

into the matrix.
 Stirring while the slurry ( melt of matrix and reinforcement ) is
solidifying improves incorporation of the particles into the matrix ally.
However the slurry must then be re – melted to a fully liquid condition
in order to enable pouring into a mould. A decrease in solidifying time
during stirring increases the percentage wetting. The particle tend to
float to the molten alloy, regardless of the speed of stirring.
 Stirring temperature
 The processing temperature is mainly influencing the
change in viscosity of Al matrix and it also accelerates the
chemical reaction between matrix and reinforcement.

 The change of viscosity influences the particle distribution

in the matrix.

 The viscosity of liquid decreased when increasing

processing temperature with increasing holding time
(starting time).
 Stirring time ( Holding time)
 When the holding time is less the particle distributed
uniformly in the matrix the liquid matrix has sufficient
viscosity in the temperature range and velocity of particle flow
is small.
 In case of large holding time the liquid has sufficient viscosity
at lower temperature but the contact time between the matrix
and reinforcement too large during this period the particles
are distributed uniformly in the liquid even though some of
particles form clusters which could be also located in the
matrix region.
Mechanical stirrer Designs
2. Preheat temperature of the
reinforcement
 The Sic particles ( Any other reinforcement ) were
preheated at a specified temperature for 2 to 3 hr to
improve their wettability in atmospheric condition.
 The preheating of Sic particles assisted in removing
surface impurities, desorption of gases and altering the
surface composition due to formation of Sic layer on
the surface.
 Preheated temperature of Mould
 It is also another important factor which helps in the defect free
casting. Preheating the permanent mould for pouring the slurry
helps in removing the entrapped gases from the mould which
ultimately helps in reducing the porosity and to enhance the
mechanical properties of the cast AMC.

 Powder Feed Rate:

 To have a good quality of casting the feed rate of powder particles

must be uniform.

 Gas injection of particles introduces a quantity of gas into the melt.

3. The distribution of reinforcement materials
 Injection of the particles entrained in an inert carrier gas into the melt

with the help of an injection gun, where the particles are mixed into the

melt as the bubbles rise through the melt;

 Addition of particles into the molten stream as the mould is filled.

 Pushing particles into melt through the use of reciprocating rods.

 Spray casting of droplets of atomized molten metal along with particles

onto a substrate.

 Dispersion of fine particles in the melt by centrifugal action.

 Zero gravity processing which involves utilizing a synergism of ultra –

high vacuum and elevated temperature for a prolonged period of time.

 Solidification of liquid material
Schematic representation of the
particle distribution during
solidification :
(a) Grain growing freely in the liquid.

(b) Particle/grain interaction occurs.

(c) Some particles are pushed by the

interface, while some others are
engulfed.

(d) The final distribution of particle

in the matrix material.
4. Wettability between reinforcement
material and matrix alloy

 The ability of the liquid to spread over a solid surface.

The basic means used to improve wetting are:

 Increasing the surface energies of the solid,

 Decreasing the surface tension of the liquid matrix alloy,

and

 Decreasing the solid liquid interfacial energy at the

particles matrix interface
Contact angle that describes wettability
 Ɵ = 00 ,Perfect
wettability
 00<Ɵ <1800 ,Partial-
wettability
 Ɵ = 1800 ,No- wettability
Methods to improve wettability
 Coating of reinforcement particles.
 Addition of alloying elements ( Mg, Ca, Ti, Zr ..)
 Heat treatment of the particles.
 Ultrasonic irradiation of the melt.
 Methods to improve wettability
 Various processes of fiber treatment by molten sodium for the
infiltration of carbon or alumina fiber by aluminum.

 The TiB2 process involving the deposition of TiB2 on carbon fiber before
infiltration in an oxygen free atmosphere by aluminum or magnesium.

 Pre-treatment of silicon carbide by dehydrated sodium tetra borate for

infiltration by molten aluminum.

 Pre-treatment of carbon by tetra isopropytitanate for infiltration by

molten aluminum or magnesium.

 Pre-treatment of B4C by one of the various alcohol or other organic

solvents for infiltration by molten aluminum at elevated temperature.
 Dispersion of solid magnesium nitride between carbon

fibres for infiltration by magnesium.

 The Lanxide TM process using magnesium alloy additive,

nitrogen containing oxygen free atmosphere and non-

disclosed temperature for infiltration by aluminum with

several types of reinforcements.

 The use of nitrogen in aiding the wettability of silicon

carbide and alumina particles by magnesium, and

 The addition of sodium tetra borate to aid the wetting of

alumina particles by aluminum alloys.

5. Porosity in the cast metal matrix composites.
 Line A represents the surface
of the melt before stirring.
 Line B is the shape of the
surface of the melt when rapid
stirring forms a vortex, and
 Line C is the surface level
when stirring is stopped.
 Line C is significantly higher
than line A, the difference
being due to gas that was
drawn into the melt by the
vortex, and entrapped
during the mixing process.
(a)As solidification progresses, the silicon carbides that already exist in the melt
are rejected in front of the advancing alpha aluminum dendrite network .

(b) At this stage, there is an accumulation of hydrogen gas in a pocket of

interdendritic liquid due to the decrease in the solubility accompanying
solidification.

(c)When the temperature reaches the eutectic temperature, the growth of pores is
limited by their abilities to expand in the remaining melt.
 6. Chemical reactions between the reinforcement
materials And the matrix alloy
 This is also the important factor which contributes to
the poor quality of cast AMC. The reaction can be
prevented by preheating of both matrix and
reinforcement before mechanical stirring. The surface
of both must be properly cleaned in order to
minimize the reaction between these two.
Advantages
 The technology is relatively simple and low cost.

 Flexible to customer requirement.

 Very fine particles to metallic melts which would

result in more uniform distribution and effective
incorporation of the reinforcement particles in to the
matrix alloy is therefore valuable and makes the
production of high performance cast metal matrix
composite more promising.
Applications
 Drive shaft for Ford car
 Cylinder liners for Honda.
 Landing gears.
 Sports car components.
 Tank armor.
Squeeze Casting (or Liquid-Metal
Forging)
 To overcome disadvantages in Stir Casting (like
porosity)
 It is a process by which molten metal solidifies
under pressure within closed dies positioned
between the plates of a hydraulic press.
 It is mainly meant for
I. Non-Ferrous Materials (Al, Mg, Cu..)
II. Pure Ferrous Materials (Grey Cast Iron..)
Fig. Schematic illustrating squeeze casting process
operations

(a)Melt charge, preheat, and lubricate

tooling.
(b)Transfer melts into die cavity
 (c) Close tooling, solidify melt under
pressure.
(d) Eject casting, clean dies, charge melt
stock.
Advantages
 Highest Mechanical properties attainable in cast
product (Since porosity level reduced)
 It is simple, economical, efficient in its use of raw
materials
 Near net shapes can be achieved in sound fully dense
casting
 Close Tolerances i.e., ~0.05mm
 100% --Casting Yield is Obtained
 Applications
 Al Alloy Piston rings for engines and disc brakes
 Automobile wheels
 Truck hubs
 Barrel Heads &Flanges
 Brass & Bronze Brushings & Gears
 Steel Missile Components & Differential pinion gears
 No. of parts in cast iron, including ductile iron,
excellent potential for automated operations at a high
rate of production, aluminum dome, ductile iron
motor shell, steel bevel gear, stainless steel blades
Recent Advances
 This process has been applied to make composite
materials at an affordable cost.
 For example a porous ceramic free form is placed in
the die which is later filled with the liquid metal in
filtrate the porous ceramic free form giving a sound
metal ceramic composite
 Stir casting of metal matrix composites was initiated
in 1968, when S. Ray introduced alumina particles
into an aluminum melt by stirring molten aluminum
alloys containing the ceramic powders .

 Stir casting is suitable for manufacturing composites

with up to 30 % volume fractions of reinforcement.