UNIT-II

Polymer composites, thermoplastics, thermosettings, manufacturing of PMC, MMC, CCC

and their applications.

POLYMER COMPOSITES:
Polymer Matrix Composites Most commercially produced composites use a polymer
matrix material often called a resin solution. There are many different polymers available
depending upon the starting raw ingredients. There are several broad categories, each with
numerous variations. The most common are known as polyester, vinyl ester, epoxy, phenolic,
polyimide, polyamide, polypropylene, polyether ether ketone (PEEK), and others. The
reinforcement materials are often fibers but can also be common ground minerals [6]. The
various methods described below have been developed to reduce the resin content of the final
product. As a rule of thumb, hand lay up results in a product containing 60% resin and 40%
fiber, whereas vacuum infusion gives a final product with 40% resin and 60% fiber content.
The strength of the product is greatly dependent on this ratio.
PMCs are very popular due to their low cost and simple fabrication methods. Use of
non-reinforced polymers as structure materials is limited by low level of their mechanical
properties, namely strength, modulus, and impact resistance.
Reinforcement of polymers by strong fibrous network permits fabrication of PMCs,
which is characterized by the following:
 High specific strength
 High specific stiffness
 High fracture resistance
 Good abrasion resistance
 Good impact resistance
 Good corrosion resistance
 Good fatigue resistance
 Low cost
THERMOPLASTICS & THERMOSETTING PLASTICS
The word plastic comes from the Greek word Plastikos, meaning “able to be shaped
and molded”. Plastics can be broadly classified into two major groups on the basis of their
chemical structure i.e. thermoplastics and thermosetting plastics.
Thermoplastics The material that softens when heated above the glass transition
temperature or melting temperature and becomes hard after cooling is called thermoplastics.
Thermoplastics can be reversibly melted by heating and solidified by cooling in limited
number of cycles without affecting the mechanical properties. On increasing the number of
recycling of thermoplastics may result in color degradation, thereby affecting their
appearance and properties. The molecules are joined end-to-end into a series of long chains,
each chain being independent of the other. Above the melting temperature, all crystalline
structure disappears and the long chain becomes randomly scattered. The molecular structure
of thermoplastic has an influence on the chemical resistance and resistance against
environmental effects like UV radiation.
The properties may also vary from optical transparency to opaque, depending on the
molecular structure. The important properties of the thermoplastics are high strength and
toughness, better hardness, chemical resistance, durability, self lubrication, transparency and
water proofing. With the application of heat, thermoplastic softens and it can be molded into
desired shapes. Some thermoplastics can be joined with the application of heat and pressure.
 There are several techniques available for the joining of thermoplastics such as
mechanical fastening, fusion bonding, hot gas welding, solvent bonding, ultrasonic welding,
induction welding, and dielectric welding.
The different types of thermoplastic are: Acrylonitrile Butadiene Styrene (ABS),
Acetals, Acrylics, Cellulosics, Fluorocarbons, Polyamides, Polycarbonates, Polyethylene
(PE), Polypropylenes (PP), Polystyrenes, Polyetheretherketone, Polyvinyl Chloride (PVC),
Liquid Crystal Polymers (LCP), Polyphenylene Sulphide (PPS) and Vinyls.

Properties of Thermoplastics:
 By heating the polymer, it turns as soft material.
 It is available in the form of solids at Room temperature.
 It is a recyclable process.
 Thermoplastic material in the form of solid is converted into Thermoplastic material
in the form of liquid which is done by the action of heating and the Vice-versa also
takes place in another direction.
 Loses Strength: By heating the thermoplastic material it loses its strength.
 Gains strength: By the action of cooling, the thermoplastic material gains strength.
 Shape change: During cooling only, the thermoplastic material changes its shape.
 Temperature: The servicing temperature of thermoplastic material is 150°C.
 Structure: The thermoplastic material exhibits Linear structure i.e. -CH2-CH2-CH2-
CH2-
 The thermoplastic material is hazardous to the environment which is less when
compared to the thermoset and rubber.
Advantages of Thermoplastics:
The advantages of thermoplastic resin composites over thermoset resin composites include
the following:
 The softening or melting by heating allows welding and thermoforming.
 The processing cycles are very short because of the absence of the chemical reaction
of crosslinking.
 Processing is easier to monitor, because there is only a physical transformation.
 Thermoplastics don’t release gases or water vapour if they are correctly dried before
processing.
 The wastes are partially reusable as virgin matter because of the reversibility of the
physical softening or melting.
 Thermoplastic resin composites are much tougher than thermosets and offer fast
processing times and good environmental performance, except against certain
solvents in some cases. Again, check eac material and its response to each solvent
likely to be encountered.
 No health hazards.
  More closely match fiber performance
 Good fire/smoke performance (interiors and fuel tanks and engine parts).
 Good fatigue performance.
 Primary structure usage.
 High temperature uses polyetheretherketone (PEEK) 250 to 300°C (482 to 572°F).
 Future possibility of resin transfer molding (RTM) around reinforcing fiber or use in
conventional application mode (i.e., pre-preg stacking). Single crystal growth versions
could be used for engine parts.
Disadvantages of Thermoplastics:
 When the temperature rises, the modulus retention decreases, due to the absence of
chemical links between macromolecules.
 For the same reason, the creep and relaxation behaviours are not as good as for the
thermosets.
 During a fire, fusibility favours dripping and annihilates final residual physical
cohesion.
 Cost.
 New process methods.
 Long-term fatigue characteristics unknown.
 Temperature to melt for repairs is very high in some cases. This could cause serious
problems for in-situ repairs to primary or secondary structures, especially if being
done near fuel tanks or hydraulic systems.
 Polyimides suffer micro cracking.
Applications:
Thermoplastics are considered to be a favorable substitute to minimize the costs. Certain
properties of thermoplastics that make them a suitable substitute material are:
 Their ability to withstand corrosive materials and corrosive environments.
 Being able to carry materials of extreme temperatures (hot or cold).
 Their capacity to handle virtually any type of fluid transport application.
 Used to manufacture the dashboards and car trims, toys, phones, handles, electrical
products, bearings, gears, rope, hinges and catches, glass frames, cables, hoses, sheet,
and windows, etc.
Thermosets The property of material becoming permanently hard and rigid after cooling
when heated above the melting temperature is called thermosets. The solidification process of
plastics is known as curing. The transformation from the liquid state to the solid state is
irreversible process, further heating of thermosets result only in the chemical decomposition.
It means that the thermosets can’t be recycled. During curing, the small molecules are
chemically linked together to form complex inter-connected network structures. This cross-
linking prevents the slippage of individual chains. Therefore, the mechanical properties
(tensile strength, compressive strength, and hardness) are not temperature dependent, as
compared to thermoplastics. Hence, thermosets are generally stronger than the
thermoplastics.The joining of thermosets by thermal processes like ultrasonic welding, laser
welding, and gas welding is not possible, but mechanical fastening and adhesive bonding
may be used for low strength applications. The different types of thermosets are Alkyds,
Allylics, Amine, Bakelite, Epoxy, Phenolic (PF), Polyester, Silicone, Polyurethane (PUR),
and Vinyl Ester.
Applications
Thermosets are commonly used for high temperature applications. Some of the common
products are electrical equipments, motor brush holders, printed circuit boards, circuit
breakers, encapsulation, kitchen utensils, handles and knobs, and spectacle lenses.Thermoset
plastics offer enhanced high-performance combination of thermal stability, chemical
resistance, and structural integrity. Thermoset components are used extensively in a wide
range of industries – and are used for applications in the automotive, appliance, electrical,
lighting, and energy markets due to excellent chemical and thermal stability along with
superior strength, hardness, and moldability.
Properties of Thermosets:
 By heating the polymer, it turns as hard material.
 It is available in the form of liquid at Room temperature.
 It is a Non-Recyclable process.
 Thermoset in the form of liquid is converted into Thermoset material in the form of
solid which is done by the action of heating and its Vice-versa is not possible.
 Gains strength: By the action of heating, the thermoset plastic material gains strength.
 No change in the strength of the thermosetting plastic is done by the action of cooling.
 Shape change: During heating only, the thermoset material changes its shape.
 Temperature: The servicing temperature of a thermoset plastic material is 300°C.
 Structure: It exhibits a Cyclic structure.
 It is hazardous to the environment which is more when compared to the thermoplastic
and less than the rubber
Advantages of Thermosets:
 Thermoset resin composites have advantages and disad"antages when compared
to thermoplastic resin composites. The advantages of thermoset resin composites over
thermnoplastic resin composites include the following:
 Thermosets will cure at lower temperatures than most thermoplastics will melt.
Therefore, thermosets can be manufactured at lower temperatures than thermoplastics.
 Two-part systems can be cured at room temperature and their cure can be speeded by
heating to approximately 80°C (176°F).
 A range of curing temperatures, particularly with epoxy systems, allows repair at
lower temperatures than the original cure.
 Tooling can be used at lower temperatures than with thermoplastics.
Disadvantages of Thermosets:
 Slow to process
 Relatively low toughness, environmental performance, and strength.
 Can be health hazards.
 Slow to repair.
MANUFACTURING / FABRICATION OF PMC
Polymer matrix composites are used extensively across a wide range of industries,
making the design and development of effective manufacturing processes of great
importance. Manufacturing techniques for polymer matrix composites (PMCs) provides an
authoritative review of the different technologies employed in the manufacture of this class of
composite. Composites are manufactured through different techniques. The techniques are
chosen based on type of fiber, resin and the size of the product. Some of the commonly used
manufacturing techniques are given below.
 Lay-up
o Hand lay-up
o Spray lay-up
o Automatic tape lay-up
 Prepregs
 Compression molding
 Bag molding
o Pressure bag molding
o Vacuum bag molding
 Autoclave molding
 Filament winding
o Helical winding
o Hoop winding
o Polar winding
 Resin transfer molding (RTM)
o Vacuum assisted RTM (VARTM)
o High-speed RTM (HSRTM)
 Pultrusion
 Molding compounds
o SMC (sheet molding compound)
o BMC (bulk molding compound)
 Injection molding
o Resin injection molding
 Extrusion method

MANUFACTURING OF MMC
A metal matrix composite (MMC) is composite material with at least two constituent
parts, one being a metal necessarily, the other material may be a different metal or another
material, such as a ceramic or organic compound. When at least three materials are present, it
is called a hybrid composite. An MMC is complementary to a cermet . A Metal Matrix
Composite (MMC) is a composite material in which one constituent is a metal or alloy
forming at least one percolating network, while the other constituent is embedded in this
metal matrix and usually serves as reinforcement. The reinforcement in MMC could be
particulate, fibers or whiskers with volume fraction ranging from a few percent to 40%.
Compared to other materials, MMCs generally have much higher strength, stiffness and wear
resistance as well as lower weight and thermal coefficient of expansion.
MMC manufacturing can be broken into three types—solid, liquid, and vapor.
 Solid state methods
 Liquid state methods
 Semi-solid state methods
 Vapor deposition
 In-situ fabrication technique
 Powder metallurgical processes, diffusion bonding, and vapour deposition are the
techniques that come under the solid state technique.
On the other hand liquid state process includes:
 Stir casting;
 Gas pressure infiltration process;
 Squeeze or pressure casting;
 Vortex casting;
 Injection method.
Particle reinforced metal matrix composites are commonly produced by means of powder
metallurgy or via melt based approaches. Both routes are potential to produce a ‘near net
shape’ product which minimizes further machining operations. Among the above methods,
the liquid state processing technique is preferred to fabricate the composite because of their
low cost and ease of fabrication.
Solid State Process /Methods:
Solid state fabrication of Metal Matrix Composites is the process, in which Metal
Matrix Composites are formed as a result of bonding matrix metal and dispersed phase due to
mutual diffusion occurring between them in solid states at elevated temperature and under
pressure. Low temperature of solid state fabrication process (as compared to Liquid state
fabrication of Metal Matrix Composites) depresses undesirable reactions on the boundary
between the matrix and dispersed (reinforcing) phases.
The fabrication of particulate reinforced MMCs from blended elemental powders involves a
number of steps prior to final consolidation
It can be divided into two categories
 Powder blending and consolidation (Powder Metallurgy)
 Foil diffusion bonding
Powder Metallurgy (PM) technique:
Powder metallurgy (PM) is a metal working process for forming precision metal
components from metal powders. The metal powder is first pressed into product shape at
room temperature. This is followed by heating (sintering) that causes the powder particles to
fuse together without melting. The parts produced by PM have adequate physical and
mechanical properties while completely meeting the functional performance characteristics.
The cost of producing a component of given shape and the required dimensional tolerances
by PM is generally lower than the cost of casting or making it as a wrought product, because
of extremely low scrap and the fewer processing steps. The cost advantage is the main reason
for selecting PM as a process of production for high – volume component which needs to be
produced exactly to, or close to, final dimensions. Parts can be produced which are
impregnated with oil or plastic, or infiltrated with lower melting point metal. They can be
electroplated, heat treated, and machined if necessary. The rate of production of parts is quite
high, a few hundreds to several thousands per hour. Industrial applications of PM parts are
several. These include self – lubricating bearings, porous metal filters and a wide range of
engineered shapes, such as gears, cams, brackets, sprockets, etc.
Process Details:
In the PM process the following three steps are followed in sequence: mixing (or
blending), compacting, and sintering.
Mixing: A homogeneous mixture of elemental metal powders or alloy powders is prepared.
Depending upon the need, powders of other alloys or lubricants may be added.
Compacting: A controlled amount of the mixed powder is introduced into a precision die
and then it is pressed or compacted at a pressure in the range 100 MPa to 1000 MPa. The
compacting pressure required depends on the characteristics and shape of the particles, the
method of mixing, and on the lubricant used. This is generally done at room temperature. In
doing so, the loose powder is consolidated and densified into a shaped model. The model is
generally called “green compact.” As is comes out of the die, the compact has the size and
shape of the finished product. The strength of the compact is just sufficient for in – process
handling and transportation to the sintering furnace.
1. With the upper punch in the withdrawn position, the empty die cavity is filled with
mixed powder.
2. The metal powder in the die is pressed by simultaneous movement of upper and lower
punches.
3. The upper punch is withdrawn, and the green compact is ejected from the die by the
lower punch.
4. The green compact is pushed out of the pressing area so that the next operating cycle
can start.

Sintering:
During this step, the green compact is heated in a protective atmosphere furnace to a
suitable temperature, which is below the melting point of the metal. Typical sintering
atmospheres are endothermic gas, exothermic gas, dissociated ammonia, hydrogen, and
nitrogen. Sintering temperature varies from metal to metal; typically these are within 70 to
90% of the melting point of the metal or alloy. Table 2.1 gives the sintering temperatures
used for various metals. Sintering time varies with size and metal of part. Table 2.1 also gives
typical range of sintering time needed for various metals. Sintering temperature and time for
various metal powders Sintering is a solid state process which is responsible for producing
physical and mechanical properties in the PM part by developing metallurgical bond among
the powder particles. It also serves to remove the lubricant from the powder, prevents
oxidation, and controls carbon content in the part. The structure and porosity obtained in a
sintered compact depend on the temperature, time, and processing details. It is not possible to
completely eliminate the porosity because voids cannot be completely closed by compaction
and because gases evolve during sintering. Porosity is an important characteristic for making
PM bearings and filters.
Foil Diffusion Bonding:
Solid-state diffusion bonding is a process by which two nominally flat interfaces can
be joined at an elevated temperature (about 50%-90% of the absolute melting point of the
parent material) using an applied pressure for a time ranging from a few minutes to a few
hours. Diffusion bonding of materials in the solid state is a process for making a monolithic
joint through the formation of bonds at atomic level, as a result of closure of the mating
surfaces due to the local plastic deformation at elevated temperature which aids interdiffusion
at the surface layers of the materials being joined. Diffusion Bonding is a solid state
fabrication method, in which a matrix in form of foils and a dispersed phase in form of long
fibers are stacked in a particular order and then pressed at elevated temperature. The finished
laminate composite material has a multilayer structure. Diffusion Bonding is used for
fabrication of simple shape parts (plates, tubes).
Variants of diffusion bonding are roll bonding and wire/fiber winding:

Liquid state methods:

Liquid state fabrication of Metal Matrix Composites involves incorporation
of dispersed phase into a molten matrix metal, followed by its Solidification. In order to
provide high level of mechanical properties of the composite, good interfacial
bonding (wetting) between the dispersed phase and the liquid matrix should be obtained.
Wetting improvement may be achieved by coating the dispersed phase particles (fibers).
Proper coating not only reduces interfacial energy, but also prevents chemical interaction
between the dispersed phase and the matrix. The particulates are incorporated into a molten
metallic matrix using various techniques. This is followed by mixing and eventual casting of
the resulting composite mixture into shaped components or billets for further fabrication.
The selection criteria for ceramic reinforcement includes,
 elastic modulus,
 tensile strength,
 density,
 melting temperature,
 thermal stability,
 size and shape of the reinforcing particles.
The methods of liquid state fabrication of Metal Matrix Composites are as follows.
 Electroplating and electroforming
 Stir casting
  Pressure infiltration
 Squeeze casting
 Spray deposition
 Reactive processing
Liquid State Process A majority of commercially viable applications are now
produced by liquid state processing because of certain inherent advantages of this processing
technique. The liquid metal is generally less expensive and easier to handle than powders.
Also the composites can be produced in a wide variety of shapes, making use of different
methods already developed in the casting industry for non-reinforced metals. Liquid state
processing technologies are currently being investigated and developed utilize a variety of
methods to physically combine the matrix and the reinforcement.
Stir casting:
Stir casting or melt stirring is used for stirring particles into a light alloy melt. The
particles are often tends to form agglomerates, which can be only dissolved by intense
stirring. However, here gas access into the melt must be absolutely avoided, since this could
lead to unwanted porosities or reactions. Careful attention must be paid to the dispersion of
the reinforcement components, so that the reactivity of the components used is coordinated
with the temperature of the melt and the duration of stirring, since reactions with the melt can
lead to the dissolution of the reinforcement components. Because of the lower surface to
volume ratio of spherical particles, reactivity is usually less critical with stirred particle
reinforcement than with fibers. The melt can be cast directly or processed with alternative
procedures such as squeeze casting or thixocasting. Melt stirring is used by the Duralcan
Company for the production of particle-strengthened aluminum alloys. At the Lanxide
Company a similar process is used, with additional reactions between the reinforcement
components and the molten matrix being purposefully promoted to obtain a qualitatively
high-grade composite material. In the reaction procedures of the Lanxide Company it may be
desirable that the reinforcement component reacts completely with the melt to form the
component in situ, which then transfers the actual reinforcement effect to the second phase in
the MMC.

Pressure infiltration:
Infiltration is a liquid state method of composite materials fabrication, in which
apreformed dispersed phase (ceramic particles, fibers, woven) is soaked in a molten matrix
metal, which fills the space between the dispersed phase inclusions. In this process, liquid
metal is forced into a fibrous preform. Pressure is applied until solidification is complete. By
forcing the molten metal through small pores of a fibrous preform, this method requires good
wettability of the reinforcement by the molten metal. Composites fabricated by this method
involves minimal reaction of reinforcement with molten metal and free of common casting
defects such as porosity and shrinkage cavities. Inexpensive for making near net shaped parts.

When the infiltration of fiber preform occurs readily, reactions between the fiber and
them molten metal can significantly degrade fiber properties. Fiber coatings applied prior to
infiltration, which improve wetting and control reactions, have been developed and can
produce impressive results. In this case, caution should be taken such that fiber coatings must
not be exposed to air prior to infiltration because surface oxidation alters the positive effects
of coating.

Squeeze Casting Infiltration:

Squeeze Casting Infiltration is a forced infiltration method of liquid phase fabrication
of Metal Matrix Composites, using a movable mold part (ram) for applying pressure on the
molten metal and forcing it to penetrate into a performed dispersed phase, placed into the
lower fixed mold part. Squeeze Casting Infiltration method is similar to the Squeeze
casting technique used for metal alloys casting.
Squeeze Casting Infiltration process has the following steps:
 A preform of dispersed phase (particles, fibers) is placed into the lower fixed mold
half.
 A molten metal in a predetermined amount is poured into the lower mold half.
 The upper movable mold half (ram) moves downwards and forces the liquid metal to
 infiltrate the preform.
 The infiltrated material solidifies under the pressure.
 The part is removed from the mold by means of the ejector pin.

The method is used for manufacturing simple small parts (automotive engine pistons from
aluminum alloy reinforced by alumina short fibers).
Spray deposition:

In this process, the reinforcement particulates are introduced into a stream of molten alloy
which is subsequently atomised by jets of inert gas. The sprayed mixture is collected on a
substrate in the form of a reinforced metal matrix billet.

Spray process in this process, droplets of molten metal are sprayed together with the
reinforcing phase and collected on a substrate where metal solidification is completed. The
critical parameters in spray processing are the initial temperature, size distribution and
velocity of the metal drops, the velocity, temperature and feeding rate of the reinforcement
and the nature and temperature of the substrate collecting the material. Most spray processes
use gasses to atomize the molten metal into fine droplet stream. One advantage of the spray
process is the fine grain size and low segregation of the resulting matrix microstructures.
Spray deposition is not a powder metallurgical process within the strict definition of
thatmterm since metal in actual powder form is not involved. It involves the atomisation of
moltenmmetal, but instead of being allowed to solidify as powder, the spray is collected on a
substrate to form billets for subsequent forging. The most common method of spray
deposition is gas assisted spray forming. In gas assisted spray forming, high pressure high
velocity inert gas jets are used to both atomise the melt stream and direct the resultant flow of
semi-molten metal droplets onto the surface of a substrate or collector which is manipulated
in order to allow the controlled build-up of deposit or preform shape. The range of materials
that are being processed in this way is extremely wide and includes Al alloys, Cu alloys,
stainless steels, high Cr alloy steels, and superalloys. The range of shapes is extensive also -
round billets, tubes strip and sheet, and near-net shape pre-forms. Clad materials are also
being produced, for example low alloy steel rolls clad with high speed steel. The sizes that
can be produced are, naturally, a function of the available plant and they are continually
rising. A recent installation will produce tube blanks weighing up to 4.5t.
Vapor deposition:
The vapor deposition process applies a thin coating to the surface of the substrate. This
coating process is used to improve the substrate's corrosion resistance, as well as the
following properties:
 Mechanical
  Electrical
 Thermal
 Optical
 Wear
There are two categories of vapor deposition processes:
1.Chemical vapor deposition (CVD): Chemical gases or vapors react on the surface
of the solid, producing a solid byproduct on the surface in the form of a thin film. Other
byproducts are volatile and leave the surface.
2.Physical vapor deposition (PVD): Encompasses several deposition technologies in
which material is released from a source and transferred to the substrate Vapor deposition
(VD) is a coating process in which materials in a vapor state are condensed through the
processes of condensation, chemical reaction or conversion to form a solid layer over a
substrate. This thin film may be applied for a number of reasons, including protection against
corrosion.

In-situ Process:
The in-situ composites are first used for the materials produced through solidification
of polyphase alloys. When the polyphase alloys solidify, they may exhibit a fine lamellar or
rod like structure of β phase in an α phase matrix. The reinforced inter-metallic alloys may be
produced by controlled solidification or by chemical reaction between a melt and solid or
gaseous phases. The schematic diagram of manufacturing in-situ composites through the
reaction of molten metal with a gas is shown in Figure.

In-Situ Processing:
In-situ processing involves chemical reactions that result in the creation of reinforcing
phase within a metal matrix. The reinforcements can be formed from the precipitation in
liquid or solid. This method provides thermodynamic compatibility at the matrix
reinforcement interface. The reinforcement surfaces are also likely to be free of
contamination and, therefore, a stronger matrix-dispersion bond can be achieved. In situ
fabrication of Metal Matrix Composite is a process, in which dispersed (reinforcing) phase is
formed in the matrix as a result of precipitation from the melt during its cooling
and Solidification.
Different types of Metal Matrix Composites may be prepared by in situ fabrication method:
1. Particulate in situ MMC – Particulate composite reinforced by in situ synthesized
dispersed phase in form of particles. Examples: Aluminum matrix reinforced by
titanium boride (TiB 2 ) particles, magnesium matrix reinforced by Mg 2 Si particles.
2. Short-fiber reinforced in situ MMC – Short-fiber composite reinforced by in situ
synthesized dispersed phase in form of short fibers or whiskers (single crystals grown
in form of short fibers). Examples: Titanium matrix reinforced by titanium boride
(TiB 2 ) whiskers, Aluminum matrix reinforced by titanium aluminide (TiAl 3 )
whiskers.
3. Long-fiber reinforced in situ MMC – Long-fiber composite reinforced by in situ
synthesized dispersed phase in form of continuous fibers. Examples: Nickel-
aluminum (Ni-Al) matrix reinforced by long continuous fibers of Mo (NiAl- 9Mo
alloy). Dispersed phases of in situ fabricated Metal Matrix Composites may consist
of inter metallic compounds, carbides, borides, oxides, one of eutectic ingredients.

Applications of in situ Metal Matrix Composites:

 Aerospace: In this industry equipment on board aircraft must be tested in situ, or in

place, to confirm everything functions properly as a system.
 Petroleum production: in situ refers to recovery techniques which apply heat or
solvents to heavy oil or bitumen reservoirs beneath the earth’s crust.
 Experimental physics: In situ refers to a method of data collection or manipulation of
a sample without exposure to an external environment.
 Biology: In situ means to examine the phenomenon exactly in place where it occurs
(i.e. without moving it to some special medium)

Manufacturing of CCC
Fabrication of Carbon-Carbon Composites by Liquid Phase Infiltration process
 Preparation of carbon/Graphite fiber preform of the desired structure and shape.
 Infiltration of the preform with a liquid precursor: petroleum pitch/phenolic resin/coal
tar.
 Pyrolysis/carbonization (chemical decomposition by heat in the absence of Oxygen)
of the polymer precursor at 1000-1830ºF (538-1000ºC) under normal or high pressure.
 Infiltration – pyrolysis cycle is repeated several (3-10) times until the desired density
is achieved.
  Graphitization heat treatment. At this stage amorphous carbon is transformed into
crystalline graphite. The temperature of the treatment may vary within the range
2700-5400°F (1500-3000°C). Typical graphitization temperature is 4530°F (2500°C).
Graphitization of carbon-carbon composites results in increase of Modulus of
Elasticity and strength of the composite.

 Preparation of C/C fiber pre-form of desired shape and structure.

 Liquid pre-cursor: Petroleum pitch/ Phenolic resin/ Coal tar.
 Pyrolysis (Chemical deposition by heat in absence of O2.
 It is processed at 540–1000°C under high pressure.
 Pyrolysis cycle is repeated 3 to 10 times for desired density.
 Heat Treatment converts amorphous C into crystalline C
 Temperature range of treatment :1500-3000°C.
Heat treatment increases Modulus of Elasticity and Strength.
Fabrication of Carbon-Carbon Composites by Chemical Vapor Deposition process
 Preparation of carbon/Graphite fiber preform of the desired structure and shape.
 Densification of the composite by Chemical Vapor Deposition (CVD) technique.
The CVD process involves infiltration of the preform with a pressurized hydrocarbon
gas (propane, methane, propylene, acetylene, benzene) at 1800-2200ºF (982-1204ºC).
The gas is pyrolyzed forming carbon deposition on the fiber surface. The process
duration is determined by the thickness of the preform, through which the
gas diffuses.
 Graphitization heat treatment. At this stage amorphous carbon is transformed into
crystalline graphite. The temperature of the treatment may vary within the range
2700-5400°F (1500-3000°C). Typical graphitization temperature is 4530°F (2500°C).
Graphitization of carbon-carbon composites results in increase of Modulus of
Elasticity and strength of the composite.
 Fabrication of Carbon-Carbon Composites by Chemical Vapor Deposition process
results in higher (as compared to Liquid Phase Infiltration technique) Modulus of
Elasticity and mechanical strength.
 Preparation of C/C fiber pre-form of desired shape and structure
 Densification of the composite by CVD technique
 Infiltration from pressurized hydrocarbon gases (Methane /Propane)at 990-1210°C
 gas is pyrolyzed from deposition on fibre surface
 Process duration depends on thickness of pre-form
 Heat treatment increases Modulus of Elasticity and Strength
 This process gives higher strength and modulus of elasticity