ABSTRACT Magnesium alloys have been increasingly used in the automotive and aircraft industry in recent years due to their Light weight Magnesium alloys have excellent specific strength and stiffness, exceptional dimensional stability, high damping capacity, and high recycle ability. Magnesium and its alloys are becoming widely recognized as playing an increasingly important role in automotive, aircraft, and electronic consumer products. Magnesium alloy metal matrix composite (MMC) containing 14 vol. % Saffil fibres. The squeeze casting process was used to produce the composites and the process variables evaluated were applied pressure, from 0.1 MPa to 120 MPa, and preform temperature from 250 °C to 750 °C

Dr R Sivasubramanian

R Maguteeswaran

V Suresh

CiteSeerX

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME 
 
217 
 
 
 
 
 
 
 
METHODOLOGY STUDY AND ANALYSIS OF MAGNESIUM 
ALLOY METAL MATRIX COMPOSITES 
R.Maguteeswaran
a*
, Dr. R.Sivasubramanian
 b
, V.Suresh 
c
 
a & c
 Assistant Professor, Department of Mechanical Engineering, Jay Shriram 
Group of Institutions, Tirupur-638660, Tamilnadu, India. 
b Professor, Department of Mechanical Engineering, Coimbatore Institute of 
Technology, Coimbatore, Tamilnadu-638660, India. 
ABSTRACT  
Magnesium alloys have been increasingly used in the automotive and aircraft 
industry in recent years due to their Light weight Magnesium alloys have excellent 
specific strength and stiffness, exceptional dimensional stability, high damping 
capacity, and high recycle ability. Magnesium and its alloys are becoming widely 
recognized as playing an increasingly important role in automotive, aircraft, and 
electronic consumer products. Magnesium alloy metal matrix composite (MMC) 
containing 14 vol. % Saffil fibres. The squeeze casting process was used to 
produce the composites and the process variables evaluated were applied pressure, 
from 0.1 MPa to 120 MPa, and preform temperature from 250 °C to 750 °C.  
 
Keywords: Metal Matrix Composite (MMC), Magnesium alloy, Mechanical 
properties, Squeeze casting. 
1.0 INTRODUCTION 
Metal composite materials have found application in many areas of daily life . 
Often it is not realized that the application makes use of composite materials. 
These materials are produced in the conventional production and processing of 
metals. Here, the Dalmatian sword with its meander structure, which results from 
welding two types of steel by repeated forging, can be mentioned. Materials like 
cast iron with graphite or steel with high carbide content, as well as tungsten 
INTERNATIONAL JOURNAL OF MECHANICAL 
ENGINEERING AND TECHNOLOGY (IJMET) 
 
ISSN 0976 – 6340 (Print) 
ISSN 0976 – 6359 (Online)  
Volume 3, Issue 2, May-August (2012), pp. 217-224 
© IAEME: www.iaeme.com/ijmet.html 
Journal Impact Factor (2011): 1.2083 (Calculated by GISI)  
www.jifactor.com 
 
 
IJMET 
© I A E M E 
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME 
 
218 
 
carbides, consisting of carbides and metallic binders, also belong to this group of 
composite materials. For many researchers the term metal matrix composites is 
often equated with the term light metal matrix composites (MMCs).Substantial 
progress in the development of light metal matrix composites has been achieved in 
recent decades, so that they could be introduced into the most important 
applications. In traffic engineering, especially in the automotive industry, MMCs 
have been used commercially in fiber reinforced pistons and aluminum crank 
cases with strengthened cylinder surfaces as well as particle-strengthened brake 
disks. 
 
 
 
2.0 LITERATURE REVIEW 
Lloyd, D. J. have mentioned [4]Particle reinforced metal matrix composites 
are now being produced commerically, and in this paper the current status of these 
materials is reviewed. The different types of reinforcement being used, together 
with the alternative processing methods, are discussed. Depending on the initial 
processing method, different factors have to be taken into consideration to produce 
a high quality billet. With powder metallurgy processing, the composition of the 
matrix and the type of reinforcement are independent of one another. However, in 
molten metal processing they are intimately linked in terms of the different 
reactivities which occur between reinforcement and matrix in the molten state. The 
factors controlling the distribution of reinforcement are also dependent on the 
initial processing method. Secondary fabrication methods, such as extrusion and 
rolling, are essential in processing composites produced by powder metallurgy, 
since they are required to consolidate the composite fully. Other methods, such as 
0
1
2
3
4
5
6
7
8
2000 2001 2003 2004 2005 2009 2012
Mg Alloys -usage in Auto industries. 
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME 
 
219 
 
spray casting, molten metal infiltration, and molten metal mixing give an 
essentially fully consolidated product directly, but extrusion, etc., can improve the 
properties by modifying the reinforcement distribution. The mechanical properties 
obtained in metal matrix composites are dependent on a wide range of factors, and 
the present understanding, and areas requiring further study, are discussed. The 
successful commercial production of metal matrix composites will finally depend 
on their cost effectiveness for different applications. This requires optimum 
methods of processing, machining, and recycling, and the routes being developed 
to achieve this are considered. 
M.S. Yong, states that paper reports the influence of process variables on a 
zirconium-free (RZ5DF) magnesium alloy metal matrix composite (MMC) 
containing 14 vol. % Saffil fibres. The squeeze casting process was used to 
produce the composites and the process variables evaluated were applied pressure, 
from 0.1 MPa to 120 MPa, and preform temperature from 250 °C to 750 °C. The 
principal findings from this research were that a minimum applied pressure of 
60 MPa is necessary to eliminate porosity and that applied pressures greater than 
100 MPa cause fibre clustering and breakage. The optimum applied pressure was 
established to be 80 MPa. It was also established that to ensure successful preform 
infiltration a preform temperature of 600 °C or above was necessary. For the 
optimum combination of a preform preheat temperature of 600 °C and an applied 
pressure of 80 MPa, UTS of 259 MPa was obtained for the composite. This 
represented an increase of 30% compared to the UTS for the squeeze cast base 
alloy. [17]. 
X.J. Wang, K. Wu, investigated the fracture behavior of SiCp/AZ91 magnesium 
matrix composite fabricated by stir casting is investigated using the in situ SEM 
technique. Experimental results show that (1) the dominant microcrack nucleation 
mode is interface decohesion in particle-dense regions because of the weak 
interface formed during the solidification process of the composite and large stress 
concentrations caused by particle segregation, (2) microcracks coalesce by the 
failure of matrix ligaments between microcracks while additional microcracks are 
initiated in the particle-dense region ahead of the coalesced microcracks, and (3) 
cracks propagate by coalescence of microcracks or along the 
particle/matrix interface. And so we come to the conclusion that the fracture 
mechanism of SiCp/AZ91 composite is interface-controlled. The in situ SEM 
observations are verified by complementary SEM studies of the fractured 
specimens of conventional tensile tests. And so, the in situ SEM observations can 
be qualitative representation on the fracture behavior of bulk 
SiCp/AZ91composite [18]. 
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME 
 
220 
 
S. Ravi Kumar briefly explained the Characterizing residual stresses in the 
reinforcement of cast composites have been studied in the present work. Micro 
Raman Spectroscopy is a unique tool for determining the strain on the reinforced 
fibres in ceramic/polymer/MMC. Stress induced Raman shifts can be used to 
determine the stress/strain in films, fibres and particulates in composites. In this 
paper, the application of Micro Raman Spectroscopy as a non-destructive 
technique in providing information on the compressional/tensile strain in 
reinforcements in metal matrix is investigated. Examples are taken 
from hybrid Mg based composites reinforced with carbon fibres, Mg2Si in situ 
reinforcement, formed by the addition of Si in to the matrix and SiC particles. The 
studies on the strain measurements in as-cast condition and its comparison after 
thermal cycling of the composites using the bandwidth measured are discussed. 
Analysis of the bandwidth offers a tool to understand that the wavenumber shift is 
strain induced. With this, the compressional state of the fibres embedded in 
the matrix can be analysed. [19]. 
M. Svoboda, stated the comparison is made between the creep characteristics of 
the unreinforced squzee -cast AZ91 and QE22 magnesium alloy and their hybrid 
composites reinforced with 7 vol.% short carbon fibres and 15 vol.% SiC 
particulates. Although the creep resistance of the reinforced AZ91 alloy is 
considerably improved by comparison with the unreinforced matrix alloy, no 
beneficial effect of hybrid reinforcement on the creep resistance of QE22 was 
found. A detailed micro structural evaluation of the materials was performed. It 
was possible to relate the creep results to the micro structural features.[20] 
 
3.0. THE PROCESSING OF MAGNESIUM MATRIX COMPOSITES 
 
A key challenge in the processing of composites is to homogeneously distribute 
the reinforcement phases to achieve a defect-free microstructure. Based on the 
shape, the reinforcing phases in the composite can be either particles or fibers. The 
relatively low material cost and suitability for automatic processing has made the 
particulate-reinforced composite preferable to the fiber-reinforced composite for 
automotive applications. 
 
The Magnesium Matrix Composites (MMC) can be processed by different 
methods as follows: 
 
1. Conventional processing 
2. Stir casting 
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME 
 
221 
 
3. Squeeze casting  
4.  Powder metallurgy 
CONVENTIONAL PROCESSING 
 
Due to the similar melting temperatures of magnesium and aluminum alloys, the 
processing of a magnesium matrix composite is very similar to that of an 
aluminum matrix composite. For example, the reinforcing phases 
(powders/fibers/whiskers) in magnesium matrix composites are incorporated into a 
magnesium alloy mostly by conventional methods such as stir casting, squeeze 
casting, and powder metallurgy. 
 
STIR CASTING 
In a stir casting process, the reinforcing phases (usually in powder form) are 
distributed into molten magnesium by mechanical stirring. Stir casting of metal 
matrix composites was initiated in 1968, when S. Ray introduced alumina particles 
into aluminum melt by stirring molten aluminum alloys containing the ceramic 
powders [8]. 
 
SQUEEZE CASTING 
 
Although the concept of squeeze casting dates back to the 1800s [6, 7], the first 
actual squeeze casting experiment was not conducted until 1931 [14]. Fig. 2 
illustrates the process of the squeeze casting of a magnesium matrix composite [9]. 
During squeeze casting, the reinforcement (either powders or fibers/whiskers) is 
usually made into a preform and placed into a casting mold. The molten 
magnesium alloy is then poured into the mold and solidified under high pressure. 
Compared with stir casting, squeeze casting has the advantages of allowing for the 
incorporation of higher volume fractions (up to 40–50%) of reinforcement into the 
magnesium alloys [9], and the selective reinforcement of a portion of a mechanical 
component.  
 
POWDER METALLURGY 
 
A variety of magnesium matrix composites have been fabricated through powder 
metallurgy such as SiC/AZ91 [42–44], TiO2/AZ91 [10], ZrO2/AZ91 [11], 
SiC/QE22 [12], and B4C/AZ80 [13]. In the powder metallurgical process, 
magnesium and reinforcement powders are mixed, pressed, degased and sintered 
at a certain temperature under a controlled atmosphere or in a vacuum. The 
advantages of this processing method include the capability of incorporating a 
relatively high volume fraction of reinforcement and fabrication of composites 
with matrix alloy and reinforcement systems that are otherwise immiscible by 
liquid casting. 
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME 
 
222 
 
 
4.0. TABLE I Mechanical properties of various Mg based materials [15–16] 
 
     0.2%YS  UTS   Ductility  Specific  
Specific 
Materials    (MPa)  (MPa)  (%)   YS   UTS 
Mg    100   258   7.7   58   148 
Mg/2%Cu   281   335   2.5   148   177 
Mg/4%Cu   355   386   1.5   170   184 
Mg/7%Cu   -  433   1.0  –   195 
Mg/2%Ni   337   370   4.8   177   194 
Mg/3%Ni   420   463   1.4   203   224 
Mg/6%Ni    -  313   0.7   –   131 
Mg/2%Ti   163   248   11.1   90   137 
Mg/4%Ti   154   239   9.5   81   126 
AZ91    263   358   7.2   145   197 
AZ91/4%Cu   299   382   6.2   142   181 
Mg/30%SiCp  229   258   2   105   118 
AZ91D/10%SiCp  135   152   0.8   69   77 
AZ91D/15%SiCp  257   289   0.7   126   142 
 
 
5.0 FABRICATION METHODOLOGY FOR MAGNESIUM ALLOY 
COMPONENTS 
 
Magnesium alloy can be cast into various types of methods including high 
pressure die casting, low pressure permanent mould, sand casting and squeeze 
methods. In this pressure die casting the alloys are injected through the nozzle to 
the extreme pressure to fill the mould now it is compressed through hydraulic 
press to lift the mould rise the compressive load with a short time (5-100ms).after 
the execution of high pressure bar up to (200 bars).then the cooling is done to high 
solidification rate of (75-1500K/S).for the high performance of the Mg-casting  
parts ,solidification of parts without blow holes and proper handling of liquid alloy 
to secure satisfactory metal quality.  
 
 
 
 
 
 
 
 
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME 
 
223 
 
 
 
Schematic Diagram for Cold Chamber Pressure Die Casting 
 
Clamp with hydraulic control 
 
 
         
 
Die 
Piston 
 
 
 
 
 
 
 
 
 
6.0. CONCLUSION 
 
The development of Magnesium MMC’s survived. The current literature of 
Magnesium MMC’s their performance were studied. The processing of MMC’s 
divided into four major process, Conventional processing, Stir casting, Squeeze 
casting, and Powder metallurgy. Manufacturing and machining was studied. In 
this studied learn about the various manufacturing and machining processes. The 
future work is the combination of any one of the Aluminum, Titanium and hybrid 
MMC’s and using suitable manufacturing processes and machining process.  
 
7.0. REFERENCES 
 
1. Hai Zhi Ye, Xing Yang Liu, Review of recent studies in magnesium matrix 
composites- Integrated Manufacturing Technologies Institute, National 
Research Council of Canada, JOURNAL OF MATERIALS SCIENCE 
39(2004)6153– 6171London, ON, Canada N6G 4X8, CRC Press Taylor 
and Francis group.(2007) 31. 
2. Z.Yang, Review on Research and Development of Magnesium Alloys, Acta 
Metall. Sin. (Engl. Lett.)Vol.21 No.5 pp313-328 Oct. 2008 
3. Karl Ulrich Kainer, Basics of Metal Matrix Composites 
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME 
 
224 
 
4. Lloyd, D. J. Particle reinforced aluminium and magnesium matrix 
composites , International Materials Reviews, Maney Publishing Volume 
39, Number 1, 1994 , pp. 1-23(23) 
5. S. RAY, “MTech Dissertation” (Indian Institute of Technology, Kanpur, 
1969). 
6. J. HOLLINGGRAK, Casting Metals, UK Patent 4371 (1819). 
7. D. K. CHERNOV, Reports of the Imperial Russian Metallurgical Society, 
Dec. 1878. 
8. I. J. POLMER, “Light Alloys,” 2nd edn. Published by Edward Arnold 
(1989) p. 169. 
9. ALAN LUO, JEAN RENAUD, ISAO NAKATSUGAWA and JACQUES 
PLOURDE, JOM July (1995) 28. 
10. A. YAMAZAKI, J . KANEKO andM. SUGAMATA, J. Jpn. Soc. Powder 
Powder Metall. (Japan) 48(10) (2001) 935. 
11. A. RUDAJEVOVA and P . LUKAC, Kovove Materialy (Slovak Republic) 
38(1) (2000) 1. 
12. C. BADINI, F. MARINO, M. MONTORSI and X. B. GUO, Mater. Sci. 
Eng. A 157 (1992) 53. 
13. J. ZHANG, Z. FAN, Y. Q. WANG and B. L. ZHOU, Scripta Materialia 
(USA) 42(11) (2000) 1101. 
14. R. E. LEE and W. J. D. JONES, J. Mater. Sci. 9 (1974) 469. 
15. S. F. HASSAN and M. GUPTA, J. Alloys Comp. 335(1/2) 2002) L10. 
16. Idem. J. Alloys Comp. 345(1/2) (2002) 246. 
17. M.S. YONG, Process optimisation for a squeeze cast magnesium alloy 
metal matrix composite, Journal of Materials Processing Technology 
,Volume 168, Issue 2, 30 September 2005, Pages 262–269. 
18. X.J. WANG, K. Wu,Study on fracture behavior of particulate reinforced 
magnesium matrix composite using in situ SEM, Composites Science and 
Technology, Volume 67, Issues 11–12, September 2007, Pages 2253–2260. 
19. S. RAVI KUMAR, Characterization of stress in reinforcements in 
magnesium based squeeze infiltrated cast hybrid composites, Materials 
Science and Engineering: A Volume 415, Issues 1–2, 15 January 2006, 
Pages 207–212. 
20. M. SVOBODA, Microstructure and creep behavior of magnesium hybrid 
composites, A, Volume, 25 July 2007, Pages 220–224. 
 


METHODOLOGY STUDY AND ANALYSIS OF MAGNESIUM ALLOY METAL MATRIX COMPOSITES

http://citeseerx.ist.psu.edu/viewdoc/download;jsessionid=C2D4D5F027935338BDB32FCD120F6E86?doi=10.1.1.1075.7385&rep=rep1&type=pdf

METHODOLOGY STUDY AND ANALYSIS OF MAGNESIUM ALLOY METAL MATRIX COMPOSITES

Abstract

Similar works

Full text

Available Versions

CiteSeerX