16
8/20/2019 4. IJME - Aluminum Metal Matrix Nano Composites - Murthy - PAID http://slidepdf.com/reader/full/4-ijme-aluminum-metal-matrix-nano-composites-murthy-paid 1/16 Aluminum Metal Matrix Nano Composites (Al Mmncs) – Manufacturing Methods: A Review 2 A!"M#N"M M$%A! MA%R#& NAN' C'M'#%$ (A! MMNC) – MAN"*AC%"R#N+ M$%,'-: A R$.#$/ N0 .0 M"R%,1 3 A0 0 R$--1 2 3  N0 $!.ARA4 5  6 C0 0 0 RA' 7 1,2 Research Scholar, Department, of Mechanical Engineering, NIT Warangal, Andhra Pradesh, India ,! Professor, MED, Department, of Mechanical Engineering, NIT Warangal, Andhra Pradesh, India A8%RAC% Applications of Al"min"m allo# str"ct"ral components are man# in a"tomo$iles, aircrafts and man# other defense s#stems d"e to their enhanced properties and strength to %eight ratios& The mechanical tri$ological and other properties of Al"min"m allo#s %o"ld $e increased considera$l# if reinforced $# nano ceramic particles s"ch as SiN, Si', Si( 2, and Al2( etc& )o%e*er, it is *er# challenging to disperse the nano ceramic particles "niforml# in the *ario"s al"min"m allo# melts for solidification process of $"l+ Al"min"m metal matri nano composites-Al MMN's.& There are se*eral methods mentioned in the literat"re for fa$rication of Al MMN's s"ch as solid state, li/"id state and deposition process& 0ario"s researchers ha*e tried *ario"s methods incl"ding po%der metall"rg#, stir casting, in sit" and other methods and e*er# method has its ad*antages and limitations and achie*ing "niform distri$"tion of reinforcements %ith nano ceramic  particles in Al allo# melts is the %hole some o$ecti*e& A thoro"gh re*ie% of *ario"s methods and proposals p"$lished d"ring last 1 #ears for man"fact"ring of Al MMN's& for enhanced properties 3comparisons %ere presented& 9$1/'R-: Al"min"m, Metal Matri Nanocomposites -Al Mmncs., 4ltrasonic 'a*itation, Nanoparticle Dispersion, Solidification Processing 0 #N%R'-"C%#'N Metal matri composites -MM's. reinforced %ith nano5particles, also called Metal Matri nano5'omposites -MMN's., and are $eing in*estigated %orld%ide in recent #ears, o%ing to their promising properties s"ita$le for a large n"m$er of f"nctional and str"ct"ral applications& The red"ced si6e of the reinforcement phase do%n to the nano5scale is s"ch that interaction of particles %ith dislocations $ecomes of significant importance and, %hen added to other strengthening effects t#picall# fo"nd in con*entional MM's, res"lts in a remar+a$le impro*ement of mechanical  properties 713!8& rocessing of Aluminum Metal Matrix Nano Composites The maor challenging in processing of composite materials is to get defect free microstr"ct"re and homogeneo"sl# distri$"tion of reinforcements& 9ased on the shape, the reinforcing phases in the composite can $e either  particles or fi$ers& The relati*el# lo% material cost and s"ita$ilit# for a"tomatic processing has made the  partic"late5reinforced composite prefera$le to the fi$er5reinforced composite for a"tomoti*e applications& Primar#  processes for man"fact"ring of AM's at ind"strial scale can $e classified into t%o main gro"ps& -A.& :i/"id state  processes; :i/"id state processes incl"de stir casting, compo casting, and s/"ee6e casting spra# casting and in situ -reacti*e. processing, "ltrasonic assisted casting& -9.& Solid state processes; Solid state process incl"de Po%der $lending www0iaset0us editoriaset0us #nternational 4ournal of Mechanical $ngineering (#4M$) #N(): 25;227<= #N($): 25;22> .ol0 73 #ssue 73 4un ; 4ul 2<>3 2;77 ? #A$%

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Aluminum Metal Matrix Nano Composites (Al Mmncs) – Manufacturing Methods: A Review  2

A!"M#N"M M$%A! MA%R#& NAN' C'M'#%$ (A! MMNC) – MAN"*AC%"R#N+

M$%,'-: A R$.#$/

N0 .0 M"R%,13 A0 0 R$--123 N0 $!.ARA45 6 C0 0 0 RA'7

1,2Research Scholar, Department, of Mechanical Engineering, NIT Warangal, Andhra Pradesh, India

,!Professor, MED, Department, of Mechanical Engineering, NIT Warangal, Andhra Pradesh, India

A8%RAC%

Applications of Al"min"m allo# str"ct"ral components are man# in a"tomo$iles, aircrafts and man# other defense

s#stems d"e to their enhanced properties and strength to %eight ratios& The mechanical tri$ological and other properties of 

Al"min"m allo#s %o"ld $e increased considera$l# if reinforced $# nano ceramic particles s"ch as SiN, Si', Si( 2, and

Al2( etc& )o%e*er, it is *er# challenging to disperse the nano ceramic particles "niforml# in the *ario"s al"min"m allo#

melts for solidification process of $"l+ Al"min"m metal matri nano composites-Al MMN's.& There are se*eral methods

mentioned in the literat"re for fa$rication of Al MMN's s"ch as solid state, li/"id state and deposition process& 0ario"s

researchers ha*e tried *ario"s methods incl"ding po%der metall"rg#, stir casting, in sit" and other methods and e*er#

method has its ad*antages and limitations and achie*ing "niform distri$"tion of reinforcements %ith nano ceramic

 particles in Al allo# melts is the %hole some o$ecti*e& A thoro"gh re*ie% of *ario"s methods and proposals p"$lished

d"ring last 1 #ears for man"fact"ring of Al MMN's& for enhanced properties 3comparisons %ere presented&

9$1/'R-: Al"min"m, Metal Matri Nanocomposites -Al Mmncs., 4ltrasonic 'a*itation, Nanoparticle Dispersion,

Solidification Processing

0 #N%R'-"C%#'N

Metal matri composites -MM's. reinforced %ith nano5particles, also called Metal Matri nano5'omposites

-MMN's., and are $eing in*estigated %orld%ide in recent #ears, o%ing to their promising properties s"ita$le for a large

n"m$er of f"nctional and str"ct"ral applications& The red"ced si6e of the reinforcement phase do%n to the nano5scale is

s"ch that interaction of particles %ith dislocations $ecomes of significant importance and, %hen added to other 

strengthening effects t#picall# fo"nd in con*entional MM's, res"lts in a remar+a$le impro*ement of mechanical

 properties 713!8&

rocessing of Aluminum Metal Matrix Nano Composites

The maor challenging in processing of composite materials is to get defect free microstr"ct"re and

homogeneo"sl# distri$"tion of reinforcements& 9ased on the shape, the reinforcing phases in the composite can $e either 

 particles or fi$ers& The relati*el# lo% material cost and s"ita$ilit# for a"tomatic processing has made the

 partic"late5reinforced composite prefera$le to the fi$er5reinforced composite for a"tomoti*e applications& Primar#

 processes for man"fact"ring of AM's at ind"strial scale can $e classified into t%o main gro"ps& -A.& :i/"id state

 processes; :i/"id state processes incl"de stir casting, compo casting, and s/"ee6e casting spra# casting and in situ

-reacti*e. processing, "ltrasonic assisted casting& -9.& Solid state processes; Solid state process incl"de Po%der $lending

www0iaset0us  editoriaset0us

#nternational 4ournal of Mechanical

$ngineering (#4M$)

#N(): 25;227<= #N($): 25;22>

.ol0 73 #ssue 73 4un ; 4ul 2<>3 2;77

? #A$%

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5< N0 .0 Murth@3 A0 0 Redd@3 N0 elvara 6 C0 0 0 Rao

follo%ed $# consolidation -PM processing., high energ# $all milling, friction Stir Process, diff"sion $onding and *apor 

deposition techni/"es& The selection of the processing ro"te depends on man# factors incl"ding t#pe and le*el of 

reinforcement loading and the degree of micro str"ct"ral integrit# desired&

<or the large5scale prod"ction of metal matri nanocomposites, the main pro$lem to face is the lo% %etta$ilit# of 

ceramic nano5particles, %hich does not allo% the preparation of MMN's $# con*entional casting processes since the res"lt

%o"ld $e an inhomogeneo"s distri$"tion of particles %ithin the matri& The high s"rface energ# leads to the formation of 

cl"sters of nanoparticles, %hich are not effecti*e in hindering the mo*ement of dislocations and can hard# generate a

 ph#sical5chemical $ond to the matri, th"s red"cing significantl# the strengthening capa$ilit# of nanoparticles& Se*eral

"ncon*entional prod"ction methods ha*e $een st"died $# researchers in order to o*ercome the %etta$ilit# iss"e, either $#

formation of the reinforcement $# liquid state process or $# solid state process addition of the ceramic reinforcement $#

specific techni/"es& )ereafter, the most st"died and s"ccessf"l methods are descri$ed $# classif#ing them into li/"id,

semisolid and solid processes&

The methods "sed for the characteri6ation of MMN's are the same of those "sed for con*entional MM's and

allo#s& (f co"rse, the do%nsi6ing of the reinforcement implies the "se of higher resol"tion techni/"es for characteri6ation

of morpholog# and local chemistr# of the constit"ents& In the literat"re, different +inds of matri metals ha*e $een co"pled

%ith se*eral t#pes of nano metric phases& 'eramic compo"nds -Si', Al2(, etc.., inter metallic materials and car$on

allotropes %ere "sed to reinforce Al, Mg, '" and other metals and allo#s& Partic"lar importance is assigned to car$on

nanot"$es -'NT., %hich are characteri6ed $# *er# high strength, stiffness and electrical cond"cti*it#& These properties

confer higher mechanical strength %hile impro*ing electrical and thermal properties of the $ase material& Moreo*er,

MMN's re*ealed to $e a$le to impro*e other interesting engineering properties, s"ch as damping capacit#, %ear resistance

and creep $eha*io"r 75=8&

This paper is aimed at thoro"gh re*ie% of *ario"s methods and proposals p"$lished d"ring last 1 #ears for 

man"fact"ring of Al MMN's& for enhanced properties 3comparisons %ere presented&

20 .AR#'" MAN"*AC%"R#N+ M$%,'- *'R R$AR#N+ A! MMNC -"R#N+ !A% *$/

1$AR

0 tir Casting

Metal matri composites %ere made $# "sing stir casting process in the #ear 1=>? 71@8& S& Ra# et&al introd"ced

al"mina particles into al"min"m allo# melt containing ceramic po%ders $# stirring 71@8& The res"ltant molten al"min"m

allo#, %ith ceramic particles, can $e "sed for sand casting, die casting& Stir casting process is s"ita$le for man"fact"ring

composites %ith *ol"me fractions @B of reinforcement 7118& In this process mechanical stirring in the f"rnace is the +e#

element& The casted composites can $e etr"ded for to red"ce porosit#C it impro*es $onding, to refine the microstr"ct"re,

homogeni6e the distri$"tion of reinforcement and %hich leads to $rea+5"p of particle agglomerates 7128& Schematic of stir 

casting design set"p sho%n in fig"re 2&1&

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Aluminum Metal Matrix Nano Composites (Al Mmncs) – Manufacturing Methods: A Review  5

*igure 2 : chematic of tir Casting -esign etup

There are some ad*antages compared to other ro"tes $# melt stirring process, simple, applica$ilit# to large

 prod"ction /"antit#, its flei$ilit#, $etter matri reinforcement $onding, and ecellent prod"cti*it# for near net shaped

components 718& The maor pro$lem associated %ith stir casting of Al"min"m MMN's s"ch as heterogeneo"s distri$"tion

of the reinforcement material, and poor %etta$ilit#& When the reinforcement particles are added to the molten metal matri,

the# float on to the melt s"rface& D"e to the s"rface tension, *er# large specific s"rface area, high interfacial energ# of 

reinforcement particles, presence of gas la#er on the ceramic particle s"rface and oide films on the melt s"rface& In this

 process mechanical stirring can $e applied for to mi the particles into the melt, %hen stirring stops, the particles tend to

 $ac+ to the s"rface 71!8& 9# gi*ing heat treatment to the reinforcement particles $efore dispersion into melt can $e

impro*ed the %etta$ilit# of reinforcement particles %ithin the molten matri allo# and the adsor$ed gases can $e remo*ed

from the particle s"rface 718& Another pro$lem is if the reinforcement particles are distri$"ted "niforml# in molten matri,

the# tend to sin+ or float to the molten melt d"e to the densit# differences $et%een the reinforcement particles and the

matri allo# melt& If the dispersion of reinforcement particles is not "niform then the# ha*e high tendenc# to agglomeration

and cl"stering& 9# inecting the particles %ith an inert gas into the melt is "sef"l in impro*ing the distri$"tion of the

reinforcement particles 71>8& When the reinforcement particle si6e red"ce to nano scales then %etta$ilit# and distri$"tion of 

reinforcement particles $ecome more diffic"lt d"e to increasing of s"rface energ# and s"rface area of nano particles, and

ca"se an increasing tendenc# for agglomeration of reinforcement particles& The flo% chart of stir casting process is sho%n

in fig"re 2&1&1&

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52 N0 .0 Murth@3 A0 0 Redd@3 N0 elvara 6 C0 0 0 Rao

*igure 200: *low Chart of tir Casting rocess

Se*eral str"ct"ral defects s"ch as particle cl"sters, porosit#, oide incl"sions and arise from casting technolog#

718& Three step miing method can $e impro*ed the %etta$ilit#, agglomeration, separation of particles and distri$"tion of 

nano5si6ed reinforcement particles, %ith addition of mechanical stirring, "ltrasonic stirring and centrif"gal force stirring

71, 1?8& The stir casting method is most economical and %ell5esta$lished metal matri composite fa$rication method 71?8&

2020 Compo Casting

Stir casting is the one of the simplest method for prod"cing al"min"m matri composites& )o%e*er, it res"lts poor 

incorporation and distri$"tion of the reinforcement particles in the matri& As the reinforcement particle si6e decreasesthere is a tendenc# of formation of agglomeration and red"ced %etta$ilit# %ith the melt& De*elopment of ne% techni/"es

for addition of *er# fine particles to metallic melts %hich %o"ld res"lt in more "niform distri$"tion and effecti*e

incorporation of the reinforcement particles into the matri allo#& Therefore %e mo*e to%ards 'ompo casting& 'ompo5

casting in*ol*es incorporation of partic"late reinforcements in the semisolid metal matri "sing mechanical miing 71=8&

ood distri$"tion of reinforcements in the metal matri and %ea+ agglomeration of particles ha*e $een achie*ed thro"gh

compo casting 72@8& 9eca"se of lo%er operating temperat"res than %hen "sing li/"id metal matrices energ# can $e sa*ed

 $# compo casting and longer tool life 7218& The 'ompo casting is sho%n in fig"re 2&2&

*igure 202: -esign etup of Compo Casting

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Aluminum Metal Matrix Nano Composites (Al Mmncs) – Manufacturing Methods: A Review  55

'ompo5casting method the particles are incorporated at semi5solid temperat"re of the allo# 7228& 'hemical

reaction $et%een molten al"min"m and silicon car$ide %ill not occ"r, d"e to the lo% relati*e operating temperat"re, the

formation of Al!' chemical compo"nd can $e a*oided *ia compo5casting 728& The melting process has t%o maor 

 pro$lems, one is ceramic particles are not %etted $# the li/"id metal matri and secondl#, the particles tend to floataccording to their densit# relati*e to the li/"id metal, the dispersion of ceramic particles are not "niform& To decrease the

 porosit# in the composite material, the s/"ee6e casting and die casting methods is needed 72!8& D"ctilit# of compo5casting

%as greater than stir casting samples %ith decreasing of particle si6e and particle percent 7228&

205 ueeDe Casting

The concept of s/"ee6e casting dates $ac+ to the 1?@@s 728& The idea %as s"ggested $# 'herno* in 1?? 728 to

appl# steam press"re to molten metal %hile $eing solidified& S/"ee6e casting eperiment %as not cond"cted "ntil 1=1

72>8& S/"ee6e casting process is the com$ination of closed die forging and gra*it# die casting& The techni/"e in %hich

metal solidifies "nder press"re %ithin closed die hal*es& S/"ee6e casting operation has $een referred to as press"recr#stalli6ation 72?8, li/"id pressing 72=8, s/"ee6e forming 7@8, and etr"sion casting 718& S/"ee6e casting fa$ricated

components ha*e s"perior %elda$ilit# and heat treata$ilit# 728& S/"ee6e casting process sho%n in fig"re 2&&

*igure 205: chematic -iagram of the ueeDe Casting Apparatus E55F

The s/"ee6e casting of al"min"m allo#s can f"lfill %ide range of re/"irements in a special %a#, %hen compared

to other prod"ction methods and materials& S/"ee6e castings $asicall# di*ided into t%o t#pes; direct and indirect, %here the

s/"ee6e press"re is applied thro"gh the die5closing p"nch itself, %here as in indirect process, the s/"ee6e press"re is

applied after closing die, $# a secondar# ram& <rom this process no shrin+age porosit#, near net shape, high degree of 

s"rface finish and dimensional acc"rac#&

207 owder Metallurg@

The non5con*entional methods ha*e $een proposed, to o*ercome the pro$lems li+e formation of cl"sters and lo%

%etta$ilit# and the high s"rface area to *ol"me ratio of ceramic compo"nds d"ring preparation process of MMN's&

Po%der metall"rg# processing method as sho%n in fig"re 2&!

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57 N0 .0 Murth@3 A0 0 Redd@3 N0 elvara 6 C0 0 0 Rao

*igure 207: chematic of rocessing of owder Metallurg@ E5GF

The po%der metall"rg# ro"tes one of the promising non con*entional method 7!8&

Po%der metall"rg# ro"te can eploit the nano particles and grain $o"ndaries strengthening capa$ilit# 78&

Po%der metall"rg# processes the process temperat"re is lo%er and ma+e the inter phase +inetics precisel# controlled& There

are traditional stages of Po%der Metall"rg#5AMMN's fa$rication incl"ding miing and $lending the po%dersC degassing

the solidified prod"ct in *ac""mC homogeni6ing thro"gh hot isostatic pressing 7>8& Al"min"m metal matri composites

%ith ceramic particles are relati*el# eas# to process are nearl# isotropic in comparison %ith fi$er reinforced composites

78& The Po%der metall"rg# process is a "ni/"e part fa$rication method that is highl# cost effecti*e in prod"cing comple

 parts at *er# close dimensional tolerances, %ith minim"m scrap loss and fe%er secondar# machining operations& )o%e*er,

this method re/"ires allo# po%ders that are generall# more epensi*e than $"l+ material, and in*ol*es complicated

 processes d"ring the material fa$rication& Th"s, po%der metall"rg# ma# not $e an ideal processing techni/"e for mass

 prod"ction&

20> ,igh $nerg@ 8all Milling

)igh energ# $all milling as a po%der processing method in*ol*es repeated deformation, %elding and fract"ring of 

 po%der particles& In this method starting po%der particles are trapped $et%een highl# +inetic colliding $alls and inner 

s"rface of the *ial, it ca"ses repeated deformation, re5%elding, fragmentation of premied po%ders res"lting in forming

dispersed particles in grain refined matri 7!>8& It is %idel# "sed techni/"e to s#nthesi6e composites %ith the addition of 

ceramic hard particles to metal allo#s increase the strength, %ear resistance and micro hardness d"ring high energ# $all

milling 7=8& )igh energ# $all milling etensi*el# emplo#ed to o$tain etended solid sol"tions 7!28, amorpho"s str"ct"res

7!8, nanocr#stalline solids 7!!8, metasata$le phases 7!8 and immisci$le components 7!>8& The sintering temperat"re can

 $e red"ced to the increased $"l+ and s"rface energies introd"ced d"ring the milling process 7!18& The method is not

s"ita$le for mass prod"ctionC maintenance is diffic"lt $eca"se of the po%der can $e milled $# pro*iding inert atmosphere&

It is time ta+ing process for to reach re/"ired properties of composites&

20B #n itu @nthesis

Al"min"m matri composites are reinforced %ith *ario"s ceramic particles s"ch as Si' 7!, !?8C AlN and Ti'

7!=8 are fa$ricated thro"gh s/"ee6e casting, stir casting and po%der metall"rg#& )o%e*er, these fa$rication processes

"s"all# re/"ire epensi*e reinforcement materials and in*ol*e comple e/"ipment and proced"res, th"s imposing

relati*el# high cost& An alternati*e ro"te for cost effecti*e fa$rication of metal matri composites is in sit" method

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Aluminum Metal Matrix Nano Composites (Al Mmncs) – Manufacturing Methods: A Review  5>

de*eloped in recent #ears %ith *ario"s reinforcement ceramic particles Si' 7@8, AlN 718 and Ti' 728& It offers a n"m$er 

of attracti*e feat"res, s"ch as good reinforcementF matri compati$ilit#, homogeneo"s distri$"tion of the reinforcing

 particles, and potentiall# lo% cost& In this method one of the reacting elements is "s"all# a constit"ent of the molten matri

allo#& The other reacting elements ma# $e either eternall# added fine po%ders or gaseo"s phases& In sit" process as sho%nin fig"re 2&>

*igure 20B: rocess of in itu @nthesis

The preheated ceramic particles are inected into the molten al"min"mC it is diffic"lt to disperse the reinforcing

 particles "niforml# in metal melts d"e to the lo% %etta$ilit# %ith the melt 78& The interface $onding ma# $e lo%ered d"e

to the porosit# and segregation at the interface $et%een the matri and reinforcement 7!8& It re/"ires the higher reaction

time temperat"re and longer holding time, %hich is greatl#, increases the cost of prod"ction&

20H ressure !ess #nfiltration

Press"re5less infiltration techni/"e is a cost effecti*e method compared %ith common processes of po%der 

metall"rg# and casting in man"fact"ring of metal matri composites containing high *ol"me fraction of reinforcements

78& The creep $eha*ior can $e impro*ed 7>8& The maor pro$lems can $e enco"ntered in the processing $# press"re5less

infiltration techni/"e, $etter %etta$ilit# and the presence of "n%anted reaction prod"cts Al!' $et%een Al and Si' 78&

Press"re5less infiltration method is s"ccessf"l, %here loose po%der $eds and performs of *ario"s ceramic materials $#

molten al"min"m allo#s has $een reported o*er the past decade 7?8&

20G "ltrasonic Assisted Casting

In scientific literat"re 4ltrasonicGs in materials processing has sho%n *ast capa$ilit# and potential 7=8& D"ring

solidification "ltrasonic *i$rations method prod"ces in finer grain si6e in cast prod"cts 7>@8& In this process main

impro*ement in con*ection and ind"ces ca*itations d"ring solidification, it leads to *ario"s ph#sical and indirect chemical

effects in the li/"id 7>18& Design of "ltrasonic assisted casting process as sho%n in fig"re 2&?&

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5B N0 .0 Murth@3 A0 0 Redd@3 N0 elvara 6 C0 0 0 Rao

*igure 20G: -esign of "ltrasonic Assisted Casting rocess

Traditional fa$rication processes, s"ch as high energ# $all milling, electroplating, rapid solidification and

sp"ttering etc, cannot $e "sed for mass prod"ction& Mechanical stirring can pro*ide onl# for $rea+ing "p large cl"sters

 pro*ide shear stress larger eno"gh to $rea+ "p smaller cl"sters of particles 7>18& In the melt there is a tendenc# of small

 particles to aggregate together to decrease the free energ# of the %hole s#stem and cl"sters ma# form in the metal matri

nano composites 7>28& The oide incl"sions can $e entering into the melt d"ring mechanical stirringC gases are ine*ita$l#

entrained in the oide incl"sions, %hich can form the porosit# in the metal after solidification 7>8& 4ltrasonic assisted

casting process the strong impact co"pling %ith local high temperat"res can potentiall# $rea+ the nanoparticle cl"sters and

clean the particle s"rface& A> allo# reinforced $# Si' nanoparticles ha*e $een fa$ricated $# "sing "ltrasonic ca*itation

method 7>!8& There are ad*antages s"ch as matri5reinforcement $onding, lo% cost processing and nearer net shape can get

form "ltrasonic stir casting method 7>8&

20 *riction tir /elding (*/)

 Nano reinforcements in a "niform are critical and diffic"lt tas+& All eisting processing techni/"es for forming

s"rface composites are $ased on li/"id phase processing at high temperat"res& It is hard to a*oid the interfacial reaction

 $et%een reinforcement and metal matri and the formation of detrimental phases& The pro$lems can $e a*oided $#

considering critical control of processing parameters to get ideal solidified microstr"ct"re in s"rface la#erC $# carr#ing at

temperat"res $elo% melting point of s"$strate& At present, m"ch attention has $een paid to a ne% s"rface modification

techni/"e i&e&, <riction stir processing& <riction stir processing has %idel# $een in*estigated, an o"tgro%th of friction stir 

%elding, has $een emplo#ed to prod"ce composite la#ers on s"rface $# "sing nano, micro and macro si6ed reinforcements

7>>8& <riction stir processing has $een carried o"t on Al"min"m @ "sing nano si6ed Si' reinforcements, %hich %ere

sho%n good metall"rgical and mechanical properties s"ch as strength, stress corrosion crac+ resistance and ecellent

fatig"e resistance 7>8& The reinforcement particle si6e and as %ell as shift of rotational direction $et%een passes effected

on the microstr"ct"re and mechanical properties of the material ha*e $een addressed in literat"re 7>?8& In this process there

is non5 cons"ma$le rotating tool and the %or+ piece to raise the local temperat"re of the material to the range %here it can

 $e plasticall# deformed easil#& The rotating tool tra*erses along the oint line, metal is essentiall# etr"ded aro"nd the tool

 $efore $eing forged $# the large do%n press"re& The stirred 6one consists of fine and e/"iaed grains prod"ced d"e to

d#namic recr#stalli6ation&

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Aluminum Metal Matrix Nano Composites (Al Mmncs) – Manufacturing Methods: A Review  5H

20< %he parI lasma intering rocess

In this process the heating is accomplished $# spar+ discharges in *oids $et%een the particles, generated $# an

instantaneo"s p"lsed direct c"rrent %hich is applied thro"gh electrodes at the top and $ottom p"nches of the graphite die,

d"e to this the particle s"rface acti*ated, p"rified and self heating phenomenon is generated $et%een the particles 7>=8&

Spar+ plasma sintering process is a no*el method for the man"fact"re of f"ll# dense materials 7@8& Spar+ plasma sintering,

has $een s"ccessf"ll# "sed in nanostr"ct"re po%der consolidation 718& Spar+ plasma sintering method is not onl# for to

 prod"ce a dense $"l+ material %ithin short processing d"ration, $"t also to fa$ricate nano5materials and to get special

microstr"ct"res 728& The con*entional method of sintering renders poor adhesion, coarse micro str"ct"re, lo% strength,

lo% hardness and densit# at higher temperat"res 78&

*igure 20<: chematic of the parI lasma intering Apparatus EHBF

The spar+ plasma sintering techni/"e is $ecoming more important $eca"se of getting enhanced material

 properties, effecti*e interface formation, cleaner grain $o"ndaries, and effecti*e shrin+age at lo%er processing temperat"re

and %ithin a shorter sintering time to consolidate po%ders compared to con*entional methods 7!8& 'om$ination of spar+ 

 plasma sintering and hot etr"sion processes demonstrated $# a"thors the feasi$ilit# of ma+ing al"min"m5car$on nano

t"$e composite materials 78&

50 C'MAR#'N '* .AR#'" MAN"*AC%"R#N+ M$%,'-

50 tir Casting

In stir casting process, if the reinforcement particles si6e is in nano then there is a tendenc# to form greater 

agglomeration and %ith poor %etta$ilit# of the particles %ith the melt& Stir casting, it s"ffers from poor incorporation and

distri$"tion of reinforcement particles in the matri& A& Sa+thi*el et al st"d#, 2>1? al"min"m allo# metal matri composites

reinforced %ith different si6es of Si' p particles, %ith increase of %eight fraction of reinforcements, there is a tendenc# of 

 porosit# formation& The mechanical properties s"ch as hardness, tensile strength and hot tensile strength -at 12@@H'.

and impact strength %ere impro*ed %ith decrease of reinforcement particle si6es 78& Thro"gh Stir casting method large

 prod"ction rates are possi$le, it is lo% cost techni/"e and nearer net shape castings can $e reached 7?8& The long stir time

gi*es "niform particle distri$"tion $"t it res"lts in too m"ch gas and oidation to Al matri& 4ltrasonic treatment is *er#

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5G N0 .0 Murth@3 A0 0 Redd@3 N0 elvara 6 C0 0 0 Rao

effecti*e to red"ce stir time, gas and oidation as %ell as dispersing particles 7=8&

502 Compocasting

In 'ompocasting process porosit# is lo%er than the stir casting process and $etter %etta$ilit# $et%een the matri

and reinforcement particles as %ell as the lo%er *ol"me shrin+age of the matri allo#& The dispersion of the ceramic

 particles is not "niform and still porosit# is presented to decrease the porosit# in the composite material, the s/"ee6e

casting and die casting methods is needed 7?@8& If the particle si6e in nano range then enhances the %etta$ilit# in $et%een

the molten matri allo# and reinforcements and impro*es the distri$"tion of the reinforcement particles in the solidified

matri 7?18& It also increases the impact energ# and the hardness of the composites and decreases their porosit#&

505 ueeDe Casting

S/"ee6e casting method impro*es the mechanical properties of Al5MMN's& This method prod"ces castings *er#

fe% defects and no porosit# 7?28& S/"ee6e cast prod"cts can $e s"ed in as cast condition in engineering applications

re/"iring high /"alit# parts, %hile chill castings and sand castings ma# $e "sed in as cast condition for non engineering

applications or engineering applications %ith less /"alit# 7?8&

507 owder Metallurg@

To refine the microstr"ct"re and o$tain homogeneo"s dispersion of ceramic reinforcements in the metal matri is

notated $# mechanical milling process as part of po%der metall"rg# techni/"e 7?!8& The parameters li+e *ol"me fraction,

green densit#, milling time, compact press"re, sintered densit# and hardness can effect on metal matri composite 7?8&

Po%der metall"rg# process can pre*ent the formation of cl"sters, and homogeneo"sl# dispersed 7?>8&

50> ,igh $nerg@ 8all Milling

)igh energ# $all milling "tili6es high energ# impacts, high fre/"enc# from $alls to repeatedl# forge po%der 

 particles together 7?8& In mit"res of d"ctile components the particles are initiall# flattened& The $rittle component

"ndergoes si6e red"ction $# fragmentation 7??8& This process is time ta+ing process to form metal matri nano composites&

Sometimes protecti*e atmosphere re/"ire pre*enting the reinforcement particles, for the formation of oides in the

composite& Thro"gho"t p"t is less, so that not s"ita$le for mass prod"ction of composites&

50B #n situ @nthesis

Al MMN's are fa$ricated thro"gh stir casting, s/"ee6e casting and po%der metall"rg#C ho%e*er theses

fa$rication methods re/"ire epensi*e reinforcement materials and in*ol*e comple e/"ipment and proced"res, relati*el#

high cost& In sit" process offers feat"res, s"ch as good reinforcement matri compati$ilit#, homogeneo"s distri$"tion of the

reinforcing particles, and lo% cost&

ressure less infiltration

In this process the li/"id metal flo%s in to the *oids in the poro"s $od# %itho"t an# eternal press"re 7?=8& It can

 pro*ide good %etta$ilit#, s"ita$le for mass prod"ction& These li/"id metal infiltration techni/"es are "s"all# assisted %ith

the "se of an eternall# applied press"re -connected to *er# high *ac""m., more epensi*e&

50H "ltrasonic Assisted Casting

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Aluminum Metal Matrix Nano Composites (Al Mmncs) – Manufacturing Methods: A Review  5

Etremel# diffic"lt for the mechanical stirring method to distri$"te and disperse nano scale particles "niforml# in

metal melts d"e to their large s"rface to *ol"me ratio and their lo% %etta$ilit# in metal melts& 9# "tili6ing this method

A> allo# reinforced $# Si' nanoparticles ha*e $een fa$ricated s"ccessf"ll# 7=@8& 4ltrasonic stirring has $een "sed in the

 p"rif#ing, degassing and refinement of metallic melt&

50G *riction tir /elding

(n s"rfaces to get nano reinforcements in a "niform manner is a critical iss"e& <riction stir process is a solid state

 processing techni/"e to o$tain a fine grained microstr"ct"re& Tho"gh <riction stir process has $een $asicall# ad*anced as a

grain refinement techni/"e, it is *er# attracti*e process for also fa$ricating composites& This method is "sed for onl#

s"rface modification to prod"ce composites %ith good mechanical properties and corrosi*e resistance %ith the addition of 

nano, micro and macro si6e reinforcements 7=18&

50 parI lasma intering rocess

Spar+ plasma sintering prod"ces high heating rates, short sintering c#cles, and lo% sintering temperat"res that

allo% sintering nanostr"ct"re materials& The spar+ plasma sintering process has $een sho%n to $e an effecti*e techni/"e for 

consolidating metallic materials incl"ding nanocomposites& This method impro*es mechanical properties %ith good

densification& It has $een reported that the high performance metal matri composites can $e fa$ricated $# "sing

mechanical allo#ing process to mi the po%ders, and follo%ed $# rapid spar+ plasma sintering 7=28&

R$*$R$NC$

1& hang, &C 'hen, D&:& 'ontri$"tion of (ro%an strengthening effect in partic"late5reinforced metal matri

nanocomposites& Mat. Sci. Eng. A 2@@?, 483–484, 1!?312&

2& hang, &C 'hen, D&:& 'onsideration of (ro%an strengthening effect in partic"late5reinforced metal matri

nanocomposites; A model for predicting their #ield strength& Scripta Mater. 2@@>, 54, 121312>&

& Sanat#5adeh, A& 'omparison $et%een c"rrent models for the strength of partic"late5reinforced metal matri

nanocomposites %ith emphasis on consideration of )all3Petch effect& Mat. Sci.  Eng. A 2@12, 531, 112311?&

!& :"o, P&C McDonald, D&T&C J", W&C Palanisam#, S&C Darg"sch, M&S&C Jia& K& A modified )all3Petch relationship in

"ltrafine5grained titani"m rec#cled from chips $# e/"al channel ang"lar pressing& Scripta Mater. 2@12, 66 , ?3 

??&

& Riccardo 'asati, Ma"ri6io 0edani, LMetal Matri 'omposites Reinforced $# Nano5ParticlesA Re*ie%

Department of Mechanical Engineering, Politecnico di Milano, 0ia :a Masa !, 2@1> Milano, Ital#&

>& Troano*a, &C :"+ac, P&C <er+el, )&C Riehemann& W& Internal friction in microcr#stalline and nanocr#stalline Mg&

 Mat. Sci. Eng. A 2@@!, @, 1!31&

& Deng, '&<&C Wang, D&&C hang, J&J&C Ma, O&J& Damping characteristics of car$on nanot"$e reinforced

al"mini"m composite& Mater. Lett. 2@@, >1, 22=321&

?& Shehata, <&C <ath#, A&C A$delhameed, M&C M"stafa, S&<& Preparation and properties of Al2( nanoparticle

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7< N0 .0 Murth@3 A0 0 Redd@3 N0 elvara 6 C0 0 0 Rao

reinforced copper matri composites $# in situ processing& Mater. Design 2@@=, @, 2>32>2&

=& <er+el, )&C Mordi+e, 9&:& Magnesi"m strengthened $# Si' nanoparticles& Mat. Sci. Eng. A 2@@1, 2=?, 1=31==&

1@& S& Ra#, MTech Dissertation, Indian Instit"te of Technolog#, 1=>=&

11& R& A& Sara*anan, M& K& S"rappa, mater& Sci&Engng& A 2> -2@@@.&

12& )& R& E6atpo"r, M& Tora$i5pari6i, S& A& Saadi, LMicrostr"ct"re and mechanical properties of etr"ded AlFAl2(

composites fa$ricated $# stir5casting process Trans& Nonferro"s Met& Soc& 'hina 2 -2@1. 12>2512>?&

1& M& Ko+, o"rnal of materials processing technolog# 1>1 -2@@. ?15?&

1!& & )ashim, :& :oone#, M& S& & )ashmi, o"rnal of Materials Processing Technolog#, 11= -2@@1. 2!52?&

1& S& A& Saadi, )& R& E6atpo"r, )& 9e#gi LMicrostr"ct"re and mechanical properties of Al5Al2( micro and nano

composites fa$ricated $# stir casting Materials Science and Engineering A 2? -2@11. ?>3?1&

1>& & )ashi, :& :oone#, M& S& & )ashmi, o"rnal of Materials Processing Technolog#, =25= -1===. 15&

1& W& ho", & M& J", o"rnal of Materials Processing Technolog# > -1==. ?5>&

1?& a#araman a#a+"mar, 9& K& Ragh"nath, T& )& Rao, LRecent De*elopment and 'hallenges in S#nthesis of 

Magnesi"m Matri Nano 'omposites5 A Re*ie% International o"rnal of :atest Research in Science and

Technolog#, 0ol&1, Iss"e 2; 1>!511&

1=& &4& Eiofor, R& & Redd#, (M != -1==. 15&

2@& M& Rosso, & Mater& Process& Technol& 1, >!5 -2@@>.&

21& :lia 9o$ie, o*ana R"6ic, 9ilana 9o$ic, Mirosla* 9a$ic, Ale+sandar 0encl, Slo$odan Mitro*ic, LMicrostr"ct"ral

characteri6ation and artificial aging of compo5casted h#$rid A>FSi'pFrp composites %ith graphite

macroparticles Materials Science Q Engineering A >12 -2@1!. 51&

22& S& A& Saadi, )& R& E6atpo"r, M& Tora$i Pari6i, L'omparision of microstr"ct"re and mechanical properties of 

A> al"min"m allo#F Al2( composites fa$ricated $# stir and compo5casting processes Materials and Design

! -2@12. 1@>5111&

2& &'& 0iala, P& <ortier, & 9o"i, & Mater& Sci& 2, 1?!251?@ -1==@.&

2!& Se*i+ ), 'an K"rna6 S, LProperties of al"mina partc"late reinforced al"min"m allo# prod"ced $# press"re die

casting Mater Des, 2, >>5? -2@@>.&

2& & )ollinggra+, 'asting Metals, 4K Patent !1 -1?1=.&

2>& 0& & Welter, Metall+d, 2, 2 -1=1.&

2& D&K& 'herno*, LReports of the Imperial R"ssain Metall"rgical Societ# -1??.&

2?& 9&9 &"l#ae*, L'r#stalli6ation of steel "nder mechanical press"re :iteinoe Proi6*odst*o, 12, -1=>@.&

2=& 0&P& Sereden+o, T& P& Malei, LPressing of components from li/"id steel Do+l& A+ad& Na"+ SSSR -1=>1. 25

2 -9ISI. Translation 2?2 -1=>2.&

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Aluminum Metal Matrix Nano Composites (Al Mmncs) – Manufacturing Methods: A Review  7

@& W& Me#er, LS/"ee6e forming, a process for prod"cing high /"alit# castings, Metall& @ -1. !>5! -1=>. -KN

Translation !, 9ISI 1!.&

1& 0& M& Pl#ats+ii, LEtr"sion 'asting, Primar# So"rces, Ne% Oor+, 1=>&

2& M&R& homashchi, A& 0i+hro*, LS/"ee6e casting; an o*er*ie% o"rnal of Materials Processing Technolog# 1@1,

15= -2@@@.&

& S&M& Se#ed Reihani, LProcessing of s/"ee6e cast Al>@>15@*olB Si' composites and their characteri6ation

Materials and Design 2, 21>5222 -2@@>.&

!& S& o"sso"s, W& J", K& Jia, LDe*loping al"min"m nanocomposites *ia se*ere plastic deformation & Ph#s;

'onf& Series 2!@, @121@> -2@1@.&

& R& 'asati, <& 9onollo, D& Dellasega, A& <a$ri6i, & Timelli, A& T"issi, M& 0edani, L E sit" A5Al2(  "ltrafine

grained nanocomposites prod"ced *ia po%der metall"rg# o"rnal of Allo#s and 'ompo"nds >1, S?>5S??-2@1!.&

>& 9& (gel, R& "r$"6, LMicrostr"ct"ral characteri6ation and tenisle properties of hot pressed Al5Si' composites

 prepared from p"re Al and '" po%ders Mater& Sci Eng& A @1, 21522@ -2@@1.&

& & (noro, M& D& Sal*ador, :& E& & 'am$ronero, L)igh temperat"re mechanical properties of al"mini"m allo#s

reinforced %ith $oron car$ide particles Mater& Sci& Eng& A !==, !215!2> -2@@=.&

?& R&S& Rana, Raesh Po"ohit,S& Das, LRe*ie% of recent st"dies in Al matri composites ISER o"rnal, ISSN 222=5

1?&

=& & M& Scamans, N& 9ir$ilis, R& & 9"chheit, L'orrosion of al"min"m and its allo#s In ShreirGs 'orrosion,

,p&1=! -2@1@.&

!@& & S& 9enamin, Met& Po%der Rep& ! ,122 -2. -1==@.&

!1& '& Santos, M& )& Koi6"mi, & K& M& <& Dag"ano, <& A& Santos, '& N& Elias, A& S& Ramos, LProperties of O5

TPFAl2( ceramic nanocomposites o$tained $# high energ# $all milling Materials Science and Engineering A

@2, >512 -2@@=.&

!2& R& Nagaraan, 9&S& M"rt#, S& Ranganathan, LNanocr#stals in Ti5$ased s#stems $# mechanical allo#ing 'hin& &

Mater& Res -S"ppl#&. , 21522@ -1==!.&

!& W& :& ohnson, )& & <echt, LMechanisms of insta$ilit# in cr#stalline allo#s %ith respect to *itrification & :ess5

'ommon Met& 1!, >5?@ -1=??.&

!!& & Ec+ert, & '& )ol6er, '& E& Krill III, W& :& ohnson, LIn*estigation of nanometer5si6ed <&'&'& metals prepared $#

 $all milling in; P& )& Shing" -Ed., Mechanical Allo#ing, Materials Science <or"m, 0ols&??5=@, Trans Tech,

S%it6erland, @512 -1==2.&

!& '&'& Koch, L Processing of nanophase materials $# high energ# $all milling in; R&D& Nanophases, &M& Sanche6

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72 N0 .0 Murth@3 A0 0 Redd@3 N0 elvara 6 C0 0 0 Rao

-Eds&., Nanocr#stalline str"ct"res, The minerals, Metals and Materials Societ#, Warrendale, PA, 1=51 -1==!.&

!>& Ismail (6demir, Sascha Ahrens, Sil+e Miic+lich, 9ernhard Wielage, LNanocr#stalline Al5Al2(p  and Si' p

composites prod"ced $# high energ# $all milling o"rnal of Materials Processing Technolog#, 2@, 111511?

-2@@?.&

!& O&)& Seoa, '&& Kang$, 'ompos& Sci& Technol, =, >!5>! -1===.&

!?& 4&A& '"rle, :& I*anche*, Trans, Nonferro"s Met& Soc, 2@, ?25?> -2@1@.&

!=& &<& nie, J&& Ma, )&M& Ding, J&<& :i", & Allo#s 'omp, !?>, 1?51=@ -2@@=.&

@& M&<& a%rah, M&)& Al#, LIn sit" formation of Al2(5Si'5 m"llite from Al5matri composites 'eramics

International 2, 2152? -2@@>.&

1& W& Dao"sh, A& <rancis, O& :in, R& erman, L An eplorator# in*estigation on the in 3sit" s#nthesis of Si'F AlNFAl

composites $# spar+ plasma sintering o"rnal of Allo#s and 'ompo"nds >22, !?5!>2 -2@1.&

2& infeng Nie, Da+"i :i, en6hao Wang, Jiangfa :i", L In5sit" s#nthesis of Si' particles $# the str"ct"ral e*ol"tion

of Ti' in Al5Si melt o"rnal of Allo#s and 'ompo"nds >1, !@5!12 -2@1!.&

& R&amaati, M&R& Toroghinead, Mater& Sci& Eng, A 2, !1!>5!11 -2@1@.&

!& M& K& Aghaanian, M&A& Roca6ella, &T& 9"r+e, L The fa$rication of metal matri composites $# a press"reles

infiltration techni/"e o"rnal of Materials Science, 2>, !!5!! -1==1.&

& J4 <"min, W4 :a%rence 'hi5man, )AN "ag5%ei, TAN Oi, L 'ompression 'reep 9eha*ior of )igh 0ol"me

<raction of Si' Particles Reinforced Al 'omposite <a$ricated $# Press"reless Infiltration 'hinese o"rnal of 

Aerona"tics 2@, 11511= -2@@.&

>& Kat6 R N, Pech5'an"l MI, Ma+hlo"f MM, L (ptim"m conditions for press"reless infiltration of Si'p performs $#

al"min"m allo#s & Mater Process Tech 1@?, >?5 -2@@@.&

& R& Asthana, & Mater& S#nth& Process& -!., 2152? -1==.&

?& &M& S%allo%e, &E& <ield, '&S& Rees, A& D"c+%orth, Acta Metall& , =>15=> -1=?=.&

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P"$lishers -2@@!.&

>@& K&S& s"slic+, && Price, Ann& Re*& Mater& Sci& 2=, 2=52> -1===.&

>1& hi%ei :i", ing#o" )an, iang"o :i, L4ltraso"nd assisted in sit" techni/"e for the s#nthesis of partic"late

reinforced al"min"m matri composites 'omposites; Part 9 !2, 2@?@52@?!, -2@11.&

>2& Rah"l "pta, 9&S&S&Daniel, &P&'ha"dhari, L4ltrasonic assisted casting of al"min"m matri composite& IIT

Roor+ee52!>>&

>& A&M&Sam"el, )&:i", <&)& Sam"el, L(n the casta$ilit# of Al5SiFSi' particle5reinforced metal matri composites;

<actors affecting fl"idit# and so"ndness, 'ompo& Sci& Technol&, 0ol !=, 1512 -1==.&

>!& & 'ao, J& :i, LMg5>nF1&BSi' nanocomposites fa$ricated $# "ltrasonic ca*itation5 $ased solidification

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Aluminum Metal Matrix Nano Composites (Al Mmncs) – Manufacturing Methods: A Review  75

 processing & Mater Sci !, 2152> -2@@?.&

>& S& Donthamsett#, N&R& Damera, P&K& ain, L 4ltrasonic 'a*itation Assisted <a$rication and 'haracteri6ation of 

A> Metal Matri Nanocomposite Reinforced %ith Si', 9!', 'NTs AISTPME, 2-2.; 25! -2@@=.&

>>& Alido+ht SA, A$dollah56adeh A, Sole#mani S, Assadi ), L Microst"rct"re and tri$ological performance of an

al"mini"m allo# $ased h#$rid composite prod"ced $# friction stir procssing Mater Des 2, 225 -2@11.&

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