29835305 particle-reinforce-composite

composite

1. Particle Particle
Reinforced Reinforced
CompositeComposite

2. INTRODUCTIONINTRODUCTION
COMPOSITES
Particle-
Reinforced
Composite
Fiber-
Reinforced
Structural

3. IntroductionIntroduction
A particle has no long dimension. A particle has no long dimension.
Particle composites consist of particles of Particle composites consist of particles of
one material dispersed in a matrix of a one material dispersed in a matrix of a
second material. second material.
Generally spherical, ellipsoidal, polyhedral, Generally spherical, ellipsoidal, polyhedral,
or irregular in shape. or irregular in shape.
Added to a liquid matrix that later solidifies Added to a liquid matrix that later solidifies
in some process. in some process.
The particles may be treated to be made The particles may be treated to be made
compatible with the matrix, or they may be compatible with the matrix, or they may be
incorporated without such treatment. incorporated without such treatment.
Particles are most often used to extend the Particles are most often used to extend the
strength or other properties of inexpensive strength or other properties of inexpensive
materials by the addition of other materials.materials by the addition of other materials.

4. Types of Particle Reinforced Types of Particle Reinforced
CompositeComposite
Large ParticleLarge Particle
““LARGE” indicate that particle-matrix interaction LARGE” indicate that particle-matrix interaction
cannot be treated on the atomic or molecular level.cannot be treated on the atomic or molecular level.
Involves large particles that are harder or stiffer than Involves large particles that are harder or stiffer than
matrix.matrix.
The reinforcing particles tend to restrain movement of The reinforcing particles tend to restrain movement of
the matrix phase in the vicinity of each particle the matrix phase in the vicinity of each particle
The matrix transfer some of the applied stress to the The matrix transfer some of the applied stress to the
particles, which bear a friction at the load.particles, which bear a friction at the load.
Bonding at the interface is necessarily important.Bonding at the interface is necessarily important.

5. Dispersion-strengthenedDispersion-strengthened
Small particles (10 to 100 nm)Small particles (10 to 100 nm)
Matrix bears most of the applied loadMatrix bears most of the applied load
Particles hinder or impede motion of Particles hinder or impede motion of
dislocationsdislocations
Plastic deformation is restrictedPlastic deformation is restricted
Improves yield and tensile strength.Improves yield and tensile strength.
Most of MMCs fall in this categoryMost of MMCs fall in this category
Metal, metallic compound, ceramic particle, Metal, metallic compound, ceramic particle,
whisker or etc., is uniformly dispersed in whisker or etc., is uniformly dispersed in
matrix medium.matrix medium.
Types of Particle Reinforced Types of Particle Reinforced
CompositeComposite

6. Orientation and GeometryOrientation and Geometry
Approximately in the same dimension Approximately in the same dimension
in all direction. (Equiaxed).in all direction. (Equiaxed).
Uniformly distributedUniformly distributed
Generally spherical, ellipsoidal, Generally spherical, ellipsoidal,
polyhedral, or irregular in shapepolyhedral, or irregular in shape

7. Particle and Fiber variablesParticle and Fiber variables
For any composite, regardless of the selection of matrix For any composite, regardless of the selection of matrix
and disperse phase (material and type), there are many and disperse phase (material and type), there are many
optionsoptions that will affect properties:that will affect properties:
Each option will
impart different
benefits to the
final part.
Also surface
coatings on the
dispersed phase

8. Large-Particle vs. Dispersion-Strengthened CompositesLarge-Particle vs. Dispersion-Strengthened Composites
Strong Particle
>500 nm
Strong Particle
<100 nm
Shear t
Dislocation stopped
Stress field of
dispersion
Dislocation shears through
the dispersion
Dispersion Strengthened
Large-Particle

9. PROCESSPROCESS

10. Particulate Reinforcement Particulate Reinforcement
ProcessingProcessing
The process where the particulate reinforcement form The process where the particulate reinforcement form
being formedbeing formed
Examples of the particulate processing:Examples of the particulate processing:
A. Powder Processing A. Powder Processing
1. Spray drying processing (Liquid) 1. Spray drying processing (Liquid)
2. Vortex Disintegrator Drying (Semi-solid) 2. Vortex Disintegrator Drying (Semi-solid)
3. Fluid Bed and Flash Drying (Moist powder) 3. Fluid Bed and Flash Drying (Moist powder)
4. Microwave Vaccum Drying (Wet powder)4. Microwave Vaccum Drying (Wet powder)
5. Spray Congealing (Liquid melts)5. Spray Congealing (Liquid melts)

11. B. GranulationB. Granulation
1. Spray Drying Granulation Granulation (Liquid)1. Spray Drying Granulation Granulation (Liquid)
2. High Shear Granulation – continuous (Powder)2. High Shear Granulation – continuous (Powder)
3. Fluid Bed Granulation (Powder)3. Fluid Bed Granulation (Powder)
4. High Shear Granulation- Batch (dry ingredients )4. High Shear Granulation- Batch (dry ingredients )
C. PelletizingC. Pelletizing
1. Layering from Liquids & Powder1. Layering from Liquids & Powder
2. Wet & Melts Granulation Pelletizing 2. Wet & Melts Granulation Pelletizing
D. Others ProcessingD. Others Processing
1. Pulverized Process1. Pulverized Process
2. Particle size reduction through hammer mill2. Particle size reduction through hammer mill
3. Particle size reduction through roller mills3. Particle size reduction through roller mills
4. Steam Drying of Fibrous Particulates 4. Steam Drying of Fibrous Particulates

12. E.g.1: Powder – Spray DryingE.g.1: Powder – Spray Drying
From liquid feedsFrom liquid feeds
One of the most important One of the most important
continuous drying continuous drying
techniques for converting techniques for converting
solutions, emulsions, and solutions, emulsions, and
slurries into powders.slurries into powders.
The liquid feed is atomized The liquid feed is atomized
into droplets which are into droplets which are
directed into a controlled directed into a controlled
flow of hot air. flow of hot air.
Particles are formed as Particles are formed as
moisture evaporates from moisture evaporates from
each droplet.each droplet.
Spray Dryer

13. E.g. 2: Granulation - Spray Drying E.g. 2: Granulation - Spray Drying
GranulationGranulation
From liquid feedFrom liquid feed
Is a continuous process where Is a continuous process where
the desired mechanism of the desired mechanism of
particle growth is layering and particle growth is layering and
simultaneous drying of the liquid simultaneous drying of the liquid
feed on the surface of the smaller feed on the surface of the smaller
granules and nuclei particles. granules and nuclei particles.
Air temperatures are high to Air temperatures are high to
achieve the required drying achieve the required drying
rates.rates.
High density, free flowing High density, free flowing
granules are produced from granules are produced from
solution and slurry feeds. solution and slurry feeds.
most suited for inorganic feeds most suited for inorganic feeds
Spray Dryer Granulator

14. E.g. 3: PelletizingE.g. 3: Pelletizing
(A)(A)Layering from liquids Layering from liquids
 A solution or suspension of the active A solution or suspension of the active
component is sprayed onto inert cores component is sprayed onto inert cores
consisting of crystals or non-pareil seeds. consisting of crystals or non-pareil seeds.
Is a multi-layer spray coating process which Is a multi-layer spray coating process which
can be performed in fluid beds, the Precision can be performed in fluid beds, the Precision
Coater™ or the Roto-Processor™.Coater™ or the Roto-Processor™.
Pellet Processor™ Roto-Processor™

15. E.g. 4: Size Reduction Through Hammer MillE.g. 4: Size Reduction Through Hammer Mill
Hammer millsHammer mills
is a machine whose purpose is to shred material into fine particles is a machine whose purpose is to shred material into fine particles
through impact force.through impact force.
essentially a steel drum: contains a vertical or horizontal cross shaped essentially a steel drum: contains a vertical or horizontal cross shaped
rotor on which pivoting hammers are mounted.rotor on which pivoting hammers are mounted.
It reduces the particle size of materials by impacting a slow moving It reduces the particle size of materials by impacting a slow moving
target with a rapidly moving hammer. target with a rapidly moving hammer.
Particles produced using a hammer mill will generally be spherical in Particles produced using a hammer mill will generally be spherical in
shape with a surface that appears polished shape with a surface that appears polished
Rotor
Hopper

16. Process Description:Process Description:
The rotor is spun at a high speed inside the The rotor is spun at a high speed inside the
drum while material is fed into a feed hopper drum while material is fed into a feed hopper
Material is impacted by the hammers on the Material is impacted by the hammers on the
ends of the rotating cross and thereby is ends of the rotating cross and thereby is
shredded and expelled through screens in the shredded and expelled through screens in the
drum drum
The design and placement of hammers is The design and placement of hammers is
determined by operating parameters such as determined by operating parameters such as
rotor speed, motor horsepower, and open area rotor speed, motor horsepower, and open area
in the screen.in the screen.

17. E.g. 5: Pulverized ProcessE.g. 5: Pulverized Process
Is the process where material has been pounded, Is the process where material has been pounded,
crush, or grind to a powder or dust.crush, or grind to a powder or dust.
Example of process: Pulverization of coalExample of process: Pulverization of coal
Is a method to improve burning efficiency and Is a method to improve burning efficiency and
maximize energy outputmaximize energy output
Typically found in power generation, steel and iron Typically found in power generation, steel and iron
manufacturing, cogeneration, cement drying, and manufacturing, cogeneration, cement drying, and
other industries that employ coal injection furnaces.other industries that employ coal injection furnaces.

18. Typical pulverizedTypical pulverized
fuel storage and firing systemfuel storage and firing system
Dust
Collector
Coal from
Bunker to
Pulverizer
To Furnace
Storage
Bin

19. Large-particle CLarge-particle Composites omposites
ProcessProcess
Processing methods of Processing methods of Large-Large-
particleparticle composites composites
Powder Forging ProcessPowder Forging Process
Calcinations ProcessCalcinations Process
Cold Pressing ProcessCold Pressing Process
Sintering ProcessSintering Process

20. Powder Forging ProcessPowder Forging Process
A powder blank is pressed to a simple shape A powder blank is pressed to a simple shape
halfway between that of a forging billet and halfway between that of a forging billet and
the required finished part.the required finished part.
““Preform” is sintered and then hot forged to Preform” is sintered and then hot forged to
finished size and shape in a closed die. finished size and shape in a closed die.
The amount of deformation involved is The amount of deformation involved is
sufficient to give a final density very closely sufficient to give a final density very closely
approaching that of the solid metal, and approaching that of the solid metal, and
consequently, the mechanical properties are consequently, the mechanical properties are
comparable with those of material forged comparable with those of material forged
from wrought bar. from wrought bar.

21. Calcinations ProcessCalcinations Process
Thermal treatment process applied to ores and other Thermal treatment process applied to ores and other
solid materials in order to bring about a thermal solid materials in order to bring about a thermal
decomposition, phase transition, or removal of a decomposition, phase transition, or removal of a
volatile fraction. volatile fraction.
Normally takes place at temperatures below the Normally takes place at temperatures below the
melting point of the product materials. melting point of the product materials.
Calcination is to be distinguished from roasting, in Calcination is to be distinguished from roasting, in
which more complex gas-solid reactions take place which more complex gas-solid reactions take place
between the furnace atmosphere and the solids.between the furnace atmosphere and the solids.
It is produced by grinding and intimately mixing clay It is produced by grinding and intimately mixing clay
and lime-bearing minerals in the proper proportions, and lime-bearing minerals in the proper proportions,
and then heating the mixture to about 1400 °C and then heating the mixture to about 1400 °C
(2550°F) in a rotary kiln.(2550°F) in a rotary kiln.

22. Cold Pressing ProcessCold Pressing Process
Bonding operation in which an assembly is Bonding operation in which an assembly is
subjected to pressure without the application subjected to pressure without the application
of heat or drying air until the adhesive of heat or drying air until the adhesive
interface has solidified and reached proper interface has solidified and reached proper
shear proportions.shear proportions.
 Used in conjunction with a sintering Used in conjunction with a sintering
technique to fabricate metal, filament technique to fabricate metal, filament
reinforced metal composites having reinforced metal composites having
uniaxially reinforced structures.uniaxially reinforced structures.

23. Sintering ProcessSintering Process
Bonding together of a porous aggregate of particles Bonding together of a porous aggregate of particles
at high temperature. at high temperature.
The thermodynamic driving force is the reduction in The thermodynamic driving force is the reduction in
the specific surface area of the particles. the specific surface area of the particles.
The mechanism usually involves atomic transport The mechanism usually involves atomic transport
over particle surfaces, along grain boundaries and over particle surfaces, along grain boundaries and
through the particle interiors.through the particle interiors.
Resulting densification, depending on the Resulting densification, depending on the
predominant diffusion pathway. predominant diffusion pathway.
Used in the fabrication of metal and ceramic Used in the fabrication of metal and ceramic
components, the agglomeration of ore fines for components, the agglomeration of ore fines for
further metallurgical processing and occurs during further metallurgical processing and occurs during
the formation of sandstones and glaciers.the formation of sandstones and glaciers.

24. Dispersion-strengthened Dispersion-strengthened
composites Processcomposites Process
Processing methods of dispersion-Processing methods of dispersion-
strengthened compositesstrengthened composites
Powder working processPowder working process
Mechanical alloying processMechanical alloying process
High pressure casting processHigh pressure casting process
Molten metal processMolten metal process
Semi-solidification processSemi-solidification process

25. Powder working processPowder working process
An alloy as a dispersing medium is pulverized and mixed with a An alloy as a dispersing medium is pulverized and mixed with a
dispersion strengthening material which is extruded at adispersion strengthening material which is extruded at a
high temperature under pressure to form a composites material. high temperature under pressure to form a composites material.
Typical powder metallurgy process:
(1) blending of the gas-atomized matrix
alloy and reinforcement in powder
form
(2) compacting (cold pressing) the
homogenous blend to roughly 80%
density
(3) degassing the preform to remove
volatile contamination, water vapor
and gasses
(4) consolidation by vacuum hot pressing
or hot isotactic pressing and
subsequently extruded, rolled or
forged

26. Mechanical alloying processMechanical alloying process
An alloy as dispersing medium is pulverized and mixed with aAn alloy as dispersing medium is pulverized and mixed with a
dispersion strengthening material, which is mechanicallydispersion strengthening material, which is mechanically
kneaded to form a composite material.kneaded to form a composite material.
Mechanical alloyingMechanical alloying creates alloy without melting but by violently deforming creates alloy without melting but by violently deforming
mixtures of different powders. Inert oxides can be introduced uniformly into the mixtures of different powders. Inert oxides can be introduced uniformly into the
microstructure. The elemental powders are microstructure. The elemental powders are milledmilled together to produce solid together to produce solid
solutions with uniform dispersions of oxide particles. solutions with uniform dispersions of oxide particles.
The dispersion-strengthened alloyed powders are then consolidated using The dispersion-strengthened alloyed powders are then consolidated using hot-hot-
isotactic pressing and extrusionisotactic pressing and extrusion to produce a solid with a very fine grain to produce a solid with a very fine grain
structure.structure.
Heat treatmentHeat treatment then induces recrystallisation, either into a coarse columnar then induces recrystallisation, either into a coarse columnar
grain structure or into a fine, equiaxed set of grains.grain structure or into a fine, equiaxed set of grains.
1
2
3
1 2 3

27. High pressure casting processHigh pressure casting process
A molten alloy as a dispersing medium is impregnated into a A molten alloy as a dispersing medium is impregnated into a
preform ofpreform of
A dispersion strengthening material under pressure and then A dispersion strengthening material under pressure and then
solidifiedsolidified
To form a composite material.To form a composite material.
Schematic view of a high pressure die casting
machine

28. Molten metal processMolten metal process
A dispersion strengthened material is added to a A dispersion strengthened material is added to a
molten alloy as a dispersing medium and then mixed molten alloy as a dispersing medium and then mixed
with stirring to form a composite material.with stirring to form a composite material.
Semisolidification processSemisolidification process
An alloy as a dispersing medium is rendered into a An alloy as a dispersing medium is rendered into a
mixed solid-liquid mixed solid-liquid
phase slurry and added with a dispersion phase slurry and added with a dispersion
strengthening material, whichstrengthening material, which
is mixed with stirring to form a composite material. is mixed with stirring to form a composite material.

29. PROPERTIESPROPERTIES

30. Mechanical Properties of Mechanical Properties of
Particulate ReinforcementParticulate Reinforcement
High specific stiffness, greater strength, and High specific stiffness, greater strength, and
good fracture properties:good fracture properties:
Influence by the microstructure of the Influence by the microstructure of the
reinforcement; such as size, shape, and spatial reinforcement; such as size, shape, and spatial
distribution of the reinforcement.distribution of the reinforcement.
Good corrosion resistance (for MMC)Good corrosion resistance (for MMC)
Lead to formation of interface between the matrix Lead to formation of interface between the matrix
reinforcement, interfacial stresses as well as high reinforcement, interfacial stresses as well as high
dislocation density in the matrixdislocation density in the matrix

31. Advantages of Particulate Advantages of Particulate
ReinforcementReinforcement
Less extensive than fibrous reinforcementsLess extensive than fibrous reinforcements
Isotropic propertiesIsotropic properties
Improves the machinability of the material. Improves the machinability of the material.
Compatible with most metalworking process and often Compatible with most metalworking process and often
fabricated to near net shapefabricated to near net shape
increase the modulus of the matrixincrease the modulus of the matrix
decrease the permeability of the matrixdecrease the permeability of the matrix
decrease the ductility of the matrix decrease the ductility of the matrix
Support higher tensile, compressive and shear stresses. Support higher tensile, compressive and shear stresses.
Ability to tailor the mechanical properties through Ability to tailor the mechanical properties through
selection of reinforcement type and volume fraction selection of reinforcement type and volume fraction
along with the metal alloyalong with the metal alloy

32. APPLICATIONSAPPLICATIONS

33. Large-particle CompositesLarge-particle Composites
Cermets (not Cermets (not cementscements) are ceramic-metal composites) are ceramic-metal composites
Cermented Carbide—cutting toolsCermented Carbide—cutting tools
WC or TiC particles (incredibly hard)WC or TiC particles (incredibly hard)
Metal matrix (Co or Ni)Metal matrix (Co or Ni)
The particles will crack under the high stresses in cutting The particles will crack under the high stresses in cutting
applications, so the matrix prevents crack propagation between applications, so the matrix prevents crack propagation between
particles by separating them.particles by separating them.
Up to 90 volume percent of particles.Up to 90 volume percent of particles.
Polymer/Carbon composites includePolymer/Carbon composites include
TiresTires
Elastomer matrix with carbon black particles (15-30 vol%).Elastomer matrix with carbon black particles (15-30 vol%).
Improved tensile strength, tear and abrasion resistance, and Improved tensile strength, tear and abrasion resistance, and
toughness.toughness.
Small particles are optimal, <50 nm.Small particles are optimal, <50 nm.

34. Ceramic-ceramic composites includeCeramic-ceramic composites include
Concrete is: Concrete is:
~70 vol% sand and gravel particles (different sizes promotes ~70 vol% sand and gravel particles (different sizes promotes
better packing).better packing).
Portland cement (ceramic/ceramic composite) is the binder Portland cement (ceramic/ceramic composite) is the binder
once water is added.once water is added.
Improved tensile, compressive, and shear response by Improved tensile, compressive, and shear response by
reinforcingreinforcing with steel rods, bars (rebar), wires, or wire with steel rods, bars (rebar), wires, or wire
mesh (ceramic-ceramic-metal composite).mesh (ceramic-ceramic-metal composite).
Steel is selected for thermal expansion coefficientSteel is selected for thermal expansion coefficient
Not corroded during cement hardeningNot corroded during cement hardening
Strong composite/matrix bond is possible, especially if the Strong composite/matrix bond is possible, especially if the
steel surface is contouredsteel surface is contoured
Pre stressingPre stressing

35. Large-particle Reinforced Large-particle Reinforced
CompositesComposites
• Examples:
Adapted from Fig.
10.10, Callister 6e.
(Fig. 10.10 is
copyright United
States Steel
Corporation, 1971.)
Spheroidite
steel
matrix:
ferrite (a)
(ductile)
particles:
cementite
(Fe3C)
(brittle)
60mm
Adapted from Fig.
16.4, Callister 6e.
(Fig. 16.4 is
courtesy Carboloy
Systems,
Department,
General Electric
Company.)
WC/Co
cemented
carbide
matrix:
cobalt
(ductile)
particles:
WC
(brittle,
hard)Vm:
10-15vol%! 600mm
Adapted from Fig.
16.5, Callister 6e.
(Fig. 16.5 is
courtesy Goodyear
Tire and Rubber
Company.)
Automobile
tires
matrix:
rubber
(compliant)
particles:
Carbon
Black
(stiffer)
0.75mm

36. Dispersion-strengthening CompositeDispersion-strengthening Composite
Thoria dispersed nickel (Ni with up to 3 vol% ThOThoria dispersed nickel (Ni with up to 3 vol% ThO
22
particles)particles)
Sintered aluminum powder (Al matrix with AlSintered aluminum powder (Al matrix with Al
22OO
33
coated Al flakes)coated Al flakes)
Nanometer AlNanometer Al
22OO
3 3 / Cu composite/ Cu composite
Particle aluminum metal matrix composites Particle aluminum metal matrix composites
(PAMMCs)(PAMMCs)
Oxides dispersion strengthened (ODS) alloysOxides dispersion strengthened (ODS) alloys
~ austenitic (Ni-based) alloys, which is strengthened by oxide dispersion and by alpha phase precipitates~ austenitic (Ni-based) alloys, which is strengthened by oxide dispersion and by alpha phase precipitates
~ ferritic (Fe-based), strengthened by an oxide dispersion, which are suitable for gas turbine chambers, high temperature sensors and ~ ferritic (Fe-based), strengthened by an oxide dispersion, which are suitable for gas turbine chambers, high temperature sensors and
heaters, diesel engine components, and components of advanced energy conversion systems. heaters, diesel engine components, and components of advanced energy conversion systems.

37. FINISHFINISH