METAL MATRIX COMPOSITES: HISTORY, STATUS, FACTORS AND FUTURE By AJITH JAMES CYRIAC Bachelor of Technology in Mechanical Engineering Cochin University of Science and Technology Cochin, Kerala, INDIA 2005 Submitted to the Faculty of the Graduate College of the Oklahoma State University in partial fulfillment of the requirements for the Degree of MASTER OF SCIENCE July 2011 METAL MATRIX COMPOSITES: HISTORY, STATUS, FACTORS AND FUTURE Thesis Approved: Dr. Jay C. Hanan Thesis Adviser Dr. Sandip P. Harimkar Dr. Ranji Vaidyanathan Dr. Mark E. Payton Dean of the Graduate College ii ACKNOWLEDGMENT As I sit down to write this page, I am filled with a great feeling of gratitude towards so many individuals who have made this endeavor possible. Above all, I would like to thank my thesis and academic advisor Dr. Jay C. Hanan for accepting me to his team and helping me with his kindness and patience throughout the project. Initially I was reluctant to take the task of doing a thesis, but his confidence in my abilities and the motivation from him and motivated me to take on such a great endeavor. I wish to thank Dr. Ranji Vaidyanathan and Dr. Sandip Harimkar for being part of my committee. I would like to thank our graduate coordinator Dr.Afshin Ghajar and his assistant Shelli Stapleton for supporting me throughout the program. I specially need to acknowledge help I received from the Kevin Drees of Edmon Low Library and Dona Donldson of O.S.U Tulsa Library for their assistance. I do not have any qualms in admitting that I would not be able to finish this project without their help. I must be thankful to my parents for believing in me throughout the graduate program. My friends Linju Jose and Nichlavos Alappatt have helped in times of need and been very supportive at times when I needed them the most. I am grateful to my team mates Ganapathi Ranjan Mahadevan, Balaji Jayakumar, and Masoud Allahakarni for helping in guiding through the procedures of preparing the thesis report. Above all, I iii kneel before God Almighty for opening my eye towards the wonders of this world even in a minuscule scale from His eyes. iv TABLE OF CONTENTS Chapter Page TABLE OF CONTENTS ................................................................................................................. v LIST OF TABLES .......................................................................................................................... ix LIST OF FIGURES ......................................................................................................................... x 1. INTRODUCTION ................................................................................................................... 1 2. History of Metal Matrix Composites following Generations .................................................. 4 2.1. Second Generation (1960s): High Performance Composites in the post-Sputnik Era: ......... 4 2.2. Third Generation (1970s & 1980s): The Search for New Markets and for the Synergy of Properties ..................................................................................................................................... 6 2.3 Fourth Generation (1990s): Hybrids and Nano-composites: ................................................. 7 3. History of Metal Matrix Composites (Chronological Analysis) .................................................. 8 3.1 Methods ................................................................................................................................. 8 3.2 Metal Matrix Composite before 20th Century ..................................................................... 11 3.3 Developments in the 20th Century Prior to 1960 ................................................................ 11 3.4 1960-1964 ............................................................................................................................ 13 3.5 1965-1969 ............................................................................................................................ 14 3.6 1970-1974 ............................................................................................................................ 16 3.7 1975-1979 ............................................................................................................................ 21 3.8 1980-1984 ............................................................................................................................ 25 3.9 1985-1989 ............................................................................................................................ 31 3.10 1990-1994 .......................................................................................................................... 36 3.11 1995-1999 .......................................................................................................................... 40 v 3.12 2000-2004 .......................................................................................................................... 44 3.13 2005-2009 .......................................................................................................................... 48 3.14 2010 ................................................................................................................................... 52 3.15 Influence of 2008-2009 recession ...................................................................................... 53 4. Patterns in the Evolution of Metal Matrix Composites .............................................................. 56 4.1 1950-1986 ............................................................................................................................ 56 4.2 1987-2010 ............................................................................................................................ 58 4.3 USA ..................................................................................................................................... 61 4.4 United Kingdom................................................................................................................... 63 4.5 U.S.S.R ................................................................................................................................ 65 4.6 Japan .................................................................................................................................... 67 4.7 China .................................................................................................................................... 69 5. Comparative Study of the 6 Journals Considered ...................................................................... 71 6. Future Opportunities and Challenges ......................................................................................... 73 7. Global Business Trends in MMC markets ................................................................................. 77 8. Factors that Affects Metal Matrix Composites .......................................................................... 78 8.1 Weight Percent ..................................................................................................................... 79 8.2 Volume Percent .................................................................................................................... 79 8.3 Particle Size ......................................................................................................................... 81 8.4 Aspect Ratio ......................................................................................................................... 85 8.5 Reinforcement Orientation ................................................................................................... 86 a) Discontinuous Fibers ..................................................................................................... 86 b) Continuous Fibers .......................................................................................................... 90 vi 8.6 Heat treatment of the matrix/Microstructure of the Matrix ........................................... 92 8.7 Reinforcement Shape and Nature ........................................................................................ 92 8.8 Raw material for reinforcement/Different reinforcements made by different manufacturers and different grades/Heat treatment of the reinforcement: ........................................................ 95 8.9 Fiber diameter ...................................................................................................................... 96 8.10 Mode of Manufacture of Composite: ................................................................................. 96 8.11 Reinforcement Distribution ............................................................................................... 98 8.12 Porosity .............................................................................................................................. 99 8.13 Fiber Spacing ................................................................................................................... 102 8.14 Interfacial Bonds .............................................................................................................. 105 8.15 Reinforcement Coatings ................................................................................................... 107 8.16 Alloys used for matrix and reinforcement ....................................................................... 109 8.17 Shape of the specimen (like