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Ceramic and metal matrix composites: route and properties

M. Rosso

Polytechnic of Turin, Dep. of Material Science and Chemical Engineering,

C.so Duca degli Abruzzi, 24 10129 Torino, Italy

The paper presents a brief state of the art of advanced ceramics, metal matrix and ceramic
matrix composites. The attention is focused on process technologies involved, applications
and future of these “potential” materials. Some experimental results are included.
The future of advanced materials is related to systems solutions, economical manufacturing
processing, diverse markets and new technologies. The new materials will provide the
opportunity for growth to a new and healthier balance, with vibrant commercial sector
delivering an improved quality of life and stronger technology base.

1. CERAMICS

With technological progress, natural materials become insufficient to meet increasing

demands on product capabilities and functions.
There are many combinations of metallic and non-metallic atoms that can combine to
form ceramic components, and also several structural arrangements are usually possible
for each combination of atoms. This led scientists to invent many new ceramic materials
to meet increasing requirements and demands in various application areas. Advanced
furnaces and heat engines played important roles in the success of the industrial
revolution, while ceramic materials were essential for thermal insulation of various types
of furnaces and engines. Electrically insulating ceramic materials were developed as
electrical and electronic technologies matured. As higher and higher frequencies and
voltages were used, the demand on ceramic dielectrics became more stringent. Also, new
specifications for the magnetic and optical properties of ceramics were developed as a part
of the new electronic and electro–optical technology revolution.
The technology of ceramics is a rapidly developing applied science in today’s world.
Technological advances result from unexpected material discoveries. On the other hand,
the new technology can drive the development of new ceramics. Currently many new
classes of materials have been devised to satisfy various new applications. Advanced
ceramics offer numerous enhancements in performance, durability, reliability, hardness,
high mechanical strength at high temperature, stiffness, low density, optical conductivity,
electrical insulation and conductivity, thermal insulation and conductivity, radiation
resistance, and so on. Ceramic technologies have been widely used for aircraft and
xxxvi M. Rosso

aerospace applications, wear-resistant parts, bioceramics, cutting tools, advanced optics,

superconductivity, nuclear reactors, etc.
Ceramics application could be categorised as structural ceramics, electrical ceramics,
ceramic composites, and ceramic coatings. These materials are emerging as the leading
class of materials needed to be improved to explore further potential applications. An
Advanced Ceramics Application Tree, which classifies its current and potential
application areas and related advantageous properties, has been developed and is shown in
figure 1. Current and future advanced ceramic products derived from the application tree
are indicated in table 1. Today, advanced ceramics have been widely used in wearing
parts, seals, low weight components and fuel cells in transportation sectors, to reduce the
weight of product, increase performance especially at high temperatures, prolong the life
cycle of a product and improve the efficiency of combustion. As advances in ceramic
technology offer potential and immediate opportunities, these materials will translate into
greater market shares in transportation sectors. On the other hand, future application is
still very limited if no breakthroughs are achieved in fundamental and applied research
[1].

A study for new application. In the frame of a research project for the development of
components to be used in critical environments, studies on the possibility of obtaining
ceramic nuts and rods were carried out by the Centre for Study and Development of
Metallurgy and Materials for mechanics at Politecnico di Torino in Alessandria.
The process of compacting and sintering powders, traditionally used in the field of
P/M, was investigated with the aim of evaluating the behaviour of alumina based powder
mixes.
Different prototype cylinders were obtained through uniaxial compaction, using a 50 t
Komage press. Since high components were pressed in cold dies, particular care was taken
to avoid the presence of density gradients, detrimental for the possibility of inducing
differential shrinkages during sintering, thus leading to deformations in the final
components. Other important considered aspects were the choice of the appropriate
compacting speed, to minimise air trapping, and all what related to the extraction of the
sample, in order to avoid the slip and stick phenomena which leads to the lamination of
the component.
Different compacting pressures were investigated, but at the end, chosen values were in
the range of 200 and 300 MPa. After cold compaction, part of cylinders were pre-sintered
while others underwent directly secondary mechanical operations: drilling, internal and
external trimming, milling and surface finishing.
This splitting was carried out in order to investigate the influence of the pre-sintering
cycle on the machinability of compacted powders.
Examples of “green” final components are shown in the figures n. 2.
Mechanically worked samples then underwent pre-sintering and final sintering; this set
of processes was performed to verify the previously calculated shrinkage, necessary to
keep the final desired dimensions of threads and of the nuts.
Following the same scheme, the former pre-sintered samples underwent mechanical
operations of drilling, trimming, etc… In this case different pre-sintering cycles had to be
investigated to mediate between workability and fragility of components.
Ceramic and metal matrix composites: route and properties xxxvii

Figure 1. Advanced ceramic application tree [1].

At the end, the length of the pre-sintering cycle (for both the cases, i.e: samples directly
machined and machined after the thermal treatment) was of 74h with a peak T of 1000°C.
Sintering was then carried out at 1600°C for 1h in air.
A general good response was obtained at the end of the whole process in terms of shapes
and dimensions, in the sense that all the obtained shrinkages (approx 20%) followed a
predictable equation in every area of the specimen.
xxxviii M. Rosso

As for the mechanical properties, hardness evaluations were carried out, as well as non
standard tensile tests in order to verify the properties of the threads.

Table 1
Current and future products for advanced ceramics [1].

Figures 2a, 2b, 2c: Ceramic nuts and rods obtained through machining in the green state, work
developed at Politecnico di Torino.
Ceramic and metal matrix composites: route and properties xxxix

2. METAL MATRIX COMPOSITES

Metal matrix composites have many advantages over monolithic metals including a higher
specific modulus, higher specific strength, better properties at elevated temperatures, lower
coefficients of thermal expansion and better wear resistance. Because of these attributes metal
matrix composites (MMCs) are under consideration for a wide range of applications.
However, on the debit side, their toughness is inferior to monolithic metals and they are more
expensive at present. In comparison with most polymer matrix composites, MMCs have
certain superior mechanical properties, namely higher transverse strength and stiffness,
greater shear and compressive strengths and better high temperature capabilities. There are
also advantages in some of the physical attributes of MMCs such as no significant moisture
absorption properties, non-inflammability, high electrical and thermal conductivities, and
resistance to most radiations [2].
MMCs, in general consist of at least two components: one is the metal matrix and second
is the reinforcement. In all cases the matrix is defined as a metal, but pure metal is rarely
used: it is generally an alloy. Some classes of MMCs, like Cermets, Diamond tools and Hard
Metals, have different and extensive applications and, even if they can be considered as
traditional materials, they are in continuous evolution [3-6].
Metal matrix composites have been extensively studied since many years, the primary support
has come from the aerospace industry for airframe and spacecraft components. More recently,
automotive, electronic and recreation industries have been working diffusively with
composites [7].
MMC reinforcements can be generally divided into five major categories: continuous
fibres, discontinuous fibres, whiskers, wires and particulate (including platelets). With
exception of wires, which are metals, reinforcements are generally ceramics. Typically these
ceramics are oxides, carbides and nitrides which are used because of their excellent
combinations of specific strength and stiffness at both ambient temperature and elevated
temperature.
The two most commonly used metal matrices are based on aluminium and titanium. Both
of these metals have comparatively low specific gravities and are available in a variety of
alloy forms. Although magnesium is even lighter, its great affinity for oxygen promotes
atmospheric corrosion and makes it less suitable for many applications. Beryllium is the
lightest of all structural metals and has a tensile modulus higher than that of steel. However, it
suffers from extreme brittleness, which is the reason for its exclusion as a potential matrix
material. Nickel and cobalt-based super alloys have also been used as matrices, but the
alloying elements in these materials tend to accentuate the oxidation of fibres at elevated
temperatures.
Aluminium and its alloys have the most attention as matrix material for MMCs and the
most common reinforcement is SiC. MMC engine applications are produced and used for
automobile engine cylinders die-cast from carbon fibre-aluminium-Al2O3 material.
The titanium alloys that are most useful in MMCs are α, β alloys and metastable β alloys.
These titanium alloys have higher tensile strength-to-weight ratios as well as better strength
retentions at 400-500°C than those of aluminium alloys.
Titanium MMCs are used in applications where performance is demanded without regard
to cost-effectiveness. This is where one obtains high-temperature performance unattainable
with conventional materials [8].
xl M. Rosso

Over the years a spectrum of processing techniques have evolved in an attempt to optimise
the microstructure and mechanical properties of MMCs. The processing methods utilised to
manufacture MMCs can be grouped according to the temperature of the metallic matrix
during processing. Accordingly, the processes can be classified into five categories: (1)
liquid-phase processes, (2) solid-liquid processes, (3) two-phase (solid-liquid) processes, (4)
deposition techniques and (5) in situ processes.
1. Liquid phase processes. In liquid phase processes, the ceramic particulates are
incorporated into a molten metallic matrix using various proprietary techniques. This is
followed by mixing and eventual casting of the resulting composite mixture into shaped
components or billets for further fabrication. The process involves a careful selection of the
ceramic reinforcement depending on the matrix alloy. In addition to compatibility with the
matrix, the selection criteria for a ceramic reinforcement include the following factors: (1)
elastic modulus, (2) tensile strength, (3) density, (4) melting temperature, (5) thermal stability,
(6) size and shape of the reinforcing particle and (7) cost. Since most ceramic materials are
not wetted by molten alloys, introduction and retention of the particulates necessitate either
adding wetting agents to the melt or coating the ceramic particulates prior to mixing. It is
possible to individuate four methods:
Liquid metal ceramic particulate mixing;
Melt infiltration;
Melt oxidation processing;
Squeeze casting or pressure infiltration.
2. Solid-phase processes. Solid phase processes involve the fabrication of particulate-
reinforced MMCs from blended elemental powders involves a number of steps prior to final
consolidation. These processes are currently used for cemented carbides and for diamond
tools, however they have good potentiality also for other systems, for examples Al based
MMC [9]. Methods that fall in this category are:
Powder metallurgy;
High energy, high rate process;
Diffusion bonding.
3. Two phase processes. Two phase processes involve the mixing of ceramic and matrix in
a region of the phase diagram where the matrix contains both solid and liquid phases. Two
phase methods are:
Ospray deposition;
Compocasting/Rheocasting;
Variable codeposition of multiphase materials.
4. Deposition techniques. Deposition techniques for MMCs fabrication involve coating
individual fibres in a tow with the matrix material needed to form the composite, followed by
diffusion bonding to form a consolidated composite plate or structural shape. Since the
composite is composed of identical units, the microstructure is more homogeneous than that
of cast composites. Several deposition techniques are available:
Immersion plating;
Electroplating;
Spray deposition;
CVD;
PVD;
Spray forming techniques.
5. In situ processes. In these techniques the reinforced phase is formed in situ. The
composite material is produced in one step from an appropriate starting alloy.
Ceramic and metal matrix composites: route and properties xli

In table 2 there is a comparison of different MMCs techniques. The route, the related cost,
the possible and most suitable applications, together with some comments are here presented.
In particular the techniques are related to diffusion processes, to powder metallurgy, to casting
techniques, as well as to spray processes.
The MMCs fabrication procedures with matrix-reinforcement best associations are shown
in table 3, with distinction between continuous and discontinuous reinforcement, while the
process routes for the production of continuous fibre-reinforced MMCs are shown in figure 3.
The wide choice between long and short fibers, as well as particulate reinforcement, figure
4, offers the possibility to design the composite with the best properties as a function of the
application requirements. An example of microstructure of spray/wind Al-12Si reinforced
composites is in figure 5 and the figure 6 describes the main process routes for the production
of discontinuous fibre, whiskers and particulate-reinforced composites.

Table 2 : Comparison of MMCs tecniques [8].

Route Cost Application Comments
Diffusion High Used to make sheets, blades, vane Handles foils or sheets of matrix
bonding shafts, structural components and filaments of reinforcing
element
Powder Medium Mainly used to produce small Both matrix and reinforcements
metallurgy objects (especially round), bolts, used in powder form; best for
pistons, valves, high-strength and particulate reinforcement; since no
heat-resistant materials melting is involved, no reaction
zone develops, showing high-
strength composite
Liquid-metal Low/Medium Used to produce structural shapes Filaments of reinforcement used
infiltration such as rods, tubes, beams with
maximum properties in a uniaxial
direction
Squeeze casting Medium Widely used in automotive industry Generally applicable to any type of
for producing different components reinforcement and may be used for
such as pistons, connecting rods, large scale manufacturing
rocker arms, cylinder heads;
suitable for making complex objects
Spray casting Medium Used to produce friction materials, Particulate reinforcement used; full-
electrical brushes and contacts, density materials can be produced
cutting and grinding tools
Compocasting/ Low Widely used in automotive, Suitable for discontinuous fibres,
Rheocasting aerospace, industrial equipment and especially particulate reinforcement
sporting goods industries; used to
manufacture bearing materials

Table 3: MMCs fabrication procedures [8].

Continuous reinforcement Discontinuous reinforcement
Processing route
Monofilament Multifilament Staple fibre Whiskers Particulate
Squeeze infiltrate preform (√) √ √ √ (√)
Spray coat or codeposit √ √ x x √
Stir mixing and casting x x (√) (√) √
Powder premix and extrude x x √ √ √
Slurry coat and hot pressing (√) √ x x x
Intercleave and diffusion bonding √ x x x x
x: not practicable; (√): not common; √: current practice
xlii M. Rosso

Fialment winding
Laminate
Monofilament between alloy Sheet,
fibres sheets with binder tape
Plasma arc
spray
Infiltration by liquid
Sheet,
metal
tape or
Multifilament
wire
fibres Infiltration by powder
metal slurry
Diffusion
bonding
Fibre preform Metal deposition as
with binder liquid (arc spray) or
vapour (CVD,PVD) Superplastic
forming
Infiltration by liquid
metal
Braze
bonding
Near net
shape
Liquid phase
bonding

Figure 3. continuous fibre-reinforced MMCs process routes [8].

Figure 4: Long fibers, short fibers and paticulate reinforcement.

The microstructure and the properties of MMCs with continuous reinforcement are quite
homogeneous, in the case of discontinuous reinforcement the homogeneity of reinforcing
particle distribution within the matrix must be evaluated in order to improve the mechanical
properties. Moreover, for applications demanding high toughness, a proper choice of metal
matrix, both in terms of chemical composition and percentage must be considered. In
particular, a higher fracture toughness can be obtained owing to a continuous and regular
ceramic network throughout the microstructure. Contrary, distributing the same volume of
ceramic particles in a metal matrix rather frequently promote the formation of reinforcement
clusters. These are weak zones that usually constitute fracture initiation sites [11].
Ceramic and metal matrix composites: route and properties xliii

Figure 5. Spray/wind Al-12Si composites reinforced with (a) stainless wire and (c) Sigma
1140 + SiC. (b) and (d) shows the interface region of SS/Al-Si and SiC/Al-Si respectively
[10].

Particulate or whiskers
Powder
metallurgy Mixing Pressing
Alloy powder

Short fibres and/or

whiskers Infiltration by molten Net shape
Squeeze component
metal
casting
Preform with binder
Billet or
ingot
Particulate
Co-spraying Plasma spray
Molten metal Extrusion
Rolling
Forging
Particulate or whiskers
Infiltration by molten
Stir casting
metal
Molten or pasty alloy

Figure 6. Discontinuous fibre, whiskers and particulate-reinforced composites process routes [8].
xliv M. Rosso

Trying to reduce this drawback, interpenetrating phase composites or co-continuous

ceramic composites, called C4, were developed [12, 13]. The production of this materials
concerns with infiltration process of silica perform with molten aluminium alloy without the
application of external pressure. The low production cost and the near net shape capability of
C4 materials are further advantages of co-continuous composites. The mechanical properties
of these materials are very satisfying and their combination with thermal and electrical
conductivity characteristics and with good tribological properties allows C4 composites very
promising for applications such as automotive disc brake rotors and callipers. To develop this
application a project is under way in the frame of the bilateral cooperation between Italy and
Slovenia [14].
There is a strong demand for the development of disc brake with improved resistance and
properties and good result have been recently obtained at Politecnico di Torino using ceramic
coatings applied on cast iron discs, as well as on Al based MMCs [15, 16].

6. Study of different ceramic coatings on cast iron and MMCs disk brakes
This work was an estimation of the possible automotive employment of a braking system
with brake disks ceramic coated coupled with metal/ceramic based friction materials. The aim
was to improve braking system performance, maintaining low production costs.

A B

Figure 7: Brake components and coated discs; view of a ceramic coating layer. The surface
appearance the coated disc (A) and of the MMC disc after the wear test at the bench.
Ceramic and metal matrix composites: route and properties xlv

In literature and already on the market there are braking disks entirely made of ceramic
materials (excellent performances) but their prices are only competitive for special car
production and not for mass production. Therefore the idea was to start from the same base
concept (the employing of ceramic materials) but obtain a good performant, costs competitive
solution.
The tested brake disks come from line production components and are employed on
medium-high car sector and from sport cars. In figure 7 are shown the main aspects attained
during the research.
The disks were plasma sprayed with different types of materials: Al2O3/TiO2 of two
granulometry range, ZrO2/Y2O3. This coating technique is the best one with high melting
point materials such as the previously indicated ceramic systems.
Ceramic coatings were tested with a thermal fatigue machine to simulate brakes work
conditions and evaluate the coating adhesion. Coated samples were also tested with the FAST
machine (friction assessment and screening test) to evaluate the friction coefficient. These
tests took about one hundred of minutes and the results were plotted as friction coefficient vs
time. Finally, coated discs were tested on the bench test apparatus and tested against a suitable
pads, to check their behaviour, resistance and life. The test results very satisfying, the photo A
and B in figure 7 show very important wear differences between the MMC coated disc (A)
and the uncoated one (B). Both the coating materials given good results without significant
differences about performances and they appear to be very profitable also for the MMC discs.

3. CERAMIC MATRIX COMPOSITES

Monolithic ceramics have reasonably high strength and stiffness but are brittle. Thus one
of the main objectives in producing ceramic matrix composites is to increase the toughness.
Naturally it is also hoped, and indeed often found, that there is a concomitant in strength and
stiffness. Figure 8 compares typical stress-strain curves for composites with that for a
monolithic ceramic; the area under the stress-strain curve is the energy of fracture of the
sample and is a measure of the toughness. It is clear from this figure that the reinforcement
with particulates and continuous fibres has lead to an increase in toughness but that the
increase is more significant for the latter. Both the monolithic and the particulate reinforced
composite fail in a catastrophic manner, which contrast with the failure of the continuous fibre
composite where a substantial load carrying capacity is maintained after failure has
commenced. therefore not only has the continuous fibre composite a better toughness but the
failure mode is more desirable. However, fibres are a more expensive reinforcement than
particles and the processing is more complex, therefore the improvement in toughness is
associated with an extra cost burden.
Ceramic matrix composite (CMC) development has lagged behind other composites for
two main reasons. First more of the processing routes for CMCs involve high temperatures
and can only be employed with high temperature reinforcements. It follows that it was not
until fibres and whiskers of high temperature ceramics, such as silicon carbide, were readily
available was there much interest in CMCs. The high temperature properties of the
reinforcement are also of importance during service. A major attribute of monolithic ceramics
is that they maintain their properties to high temperatures and this characteristic is only
retained in CMCs if the reinforcements also have good high temperature properties. Hence,
there is only limited interest in toughening ceramics by incorporation of reinforcements of
materials, such as ductile metals, that lose their strength and stiffness at intermediate
temperatures.
xlvi M. Rosso

Figure 8. Schematic force-displacement curves for a monolithic ceramic and CMCs

illustrating the greater energy of fracture of the CMCs [2].

The second factor that has hindered the progress of CMCs is also concerned with the high
temperatures usually employed for production. Differences in coefficients of thermal
expansion, α, between the matrix and the reinforcement lead to thermal stresses on cooling
from the processing temperature. However, whereas the thermal stresses can generally be
relieved in metal matrix composites by plastic deformation of the matrix, this is not possible
for CMCs and cracking of the matrix can result. The nature of the cracking depends on the
whether the reinforcement contracts more or less than the matrix on cooling as their
determines the character (tensile or compressive) of the local thermal stresses. If αR for a
particulate reinforcement is great than that for the matrix αM then the circumferential cracks
may be produced in the matrix, and for αR < αM radial cracks may be found. With a fibre
reinforcement, when αR > αM the axial tensile stresses induced in the fibres produce an
overall net residual compressive stresses in the matrix and, as the fibres contract, there is a
tendency for them to pull away from the matrix. The stress situation is reversed when αR <
αM and cracking of the matrix due to the axial tensile stresses may occur. Clearly there has to
be some matching of the coefficients of thermal expansion in order to limit these problems.
Ceramic fibres such as SiC and Si3N4 use polysilane as the base material. CMCs, in which
ceramic or glass matrices are reinforced with continuous fibres, chopped fibres, whiskers,
platelets or particulates, are emerging as a class of advanced engineering structural materials.
They currently have limited high-temperature applications but a large potential for much
wider use in military, aerospace and commercial applications such as energy-efficient systems
and transportation.
There are also other specialty CMCs such as nanocomposites (made from reactive
powders) and electroceramics. CMCs are unique in that they combine low density with high
modulus, strength and toughness (contrasted with monolithic ceramics) and strength retention
at high temperatures. Many have good corrosion and erosion characteristics for high
temperature applications. CMCs have been used in jet fighters. Industrial uses of CMCs
include furnace materials, energy conversion systems, gas turbines and heat engines.
Ceramic and metal matrix composites: route and properties xlvii

Processing methods can be broken down into two broad groups: powder consolidation and
chemically based methods. The latter class consists of:
Melt processing;
Hot pressing;
Slip casting and low-pressure sinter;
Reaction sinter;
Pressureless sinter;
Slurry;
Chemical vapour infiltration;
Directed melt oxidation;
Sol-gel processing;
Self-propagated high temperature synthesis or combustion synthesis.
Figure 9 is an example of sintered glass/spinel composite.

Figure 9. Photomicrographs of glass/spinel composites [17].

Table 4 shows the main processing routes for CMCs and their matrices and table 5 is a
detailed scheme of continuous fibre reinforced CMCs.
Table 4.
Main processing routes for CMCs [8].
Processing route Matrices
Chemical vapour infiltration Carbides, nitride carbon, oxides, borides
Viscous phase hot pressing (2D performs) Glasses, ceramic-glasses
Sol-gel route (2D, 3D performs) Oxides
Polymer precursor route (3D performs) SiC, SixNy, SixCyNz
Liquid metal infiltration Si SiC
Gas-metal reaction Oxide (Al, nitrides [Al, Zn, Ti])
Solid-state hot pressing SiC, Si3N4
Prepreg curing and pyrolysis SiC, Si3N4
Hot pressing (2D preforms) Oxides
xlviii M. Rosso

Table 5
Some processes for continuous fibre-reinforced CMCs [8].
Processing method Advantages Disadvantages Fibre Matrix T range [1]
I. SLURRY
INFILTRATION Commercially developed. Limited max. temperature Graphite Glass- 800-1000°C
a) Glass ceramic Good mechanical properties. due to matrix. ceramic
matrix Needs to be hot pressed, Nicalon Glass- 800-1000°C
expensive. ceramic
Formations of complex
shapes is difficult
b) Ceramic matrix
1. Sintered matrix Potentilally inexpensive. Shrinkage during sintering Alumina 800-1400°C
Could produce complex cracks matrix. SiC 800-1600°C
shapes. Temperature limit due to Si3N4 800-1500°C
glassy phase.
2. “Cement Inexpensive. Relatively poor properties Graphite Cements 400-1400°C
bonded matrix” Ability to produce large to date. Nicalon
complex shapes. “New”
Low temperature processing. fibres
3. Reaction Good mechanical properties. Has required hotpressing of Nicalon Si3N4 800-1500°C
bonded matrix Pressureless densification. Si powder in silicon nitride SiC 800-1600°C
system prior to reaction “New”
bonding. fibres
Simple shapes only.
II. SOL-GEL & Good matrix composition Low yields. Nicalon Nonoxide 800-1200°C
POLYMER control. Very large shrinkage. Alumina 800-1400°C
PROCESSING Easy to infiltrate fibres. Woul require multiple Silicates
Lower densification infiltration/densification
temperature. steps.
No promising results
reported.
High melting temperatures Graphite Alumina 800-1100°C
Potentially inexpensive. would damage fibres. Nicalon Oxides 800-1100°C
III. MELT Should be easy to infiltrate “New”
INFILTRATION fibres. fibres
a) Ceramic melt Lower shrinkage on
solidification.
b) Metal melt, Potentially inexpensive. Difficult to control Graphite Alumina 800-1200°C
followed by Cermet type material. chemistry and produce all Nicalon B4 C 800-1200°C
oxidation ceramic system. “New” SiC 800-1200°C
Difficult to envision in use fibres
for large, complex parts for
aerospace applications.
IV. CHEMICAL Has been commercially Slow and expensive. Nicalon SiC 800-1600°C
VAPOUR developed. Requires iterative process. Nextels HfC 800-1800°C
INFILTRATION Best mechanical properties. Never achieved full density. Nitrides
a) General approach Considerable flexibility in Capital intensive. Oxides
fibres and matrices. Borides
High quality matrix, very
pure.
Little fibre damage.
In situ fibre surface
trestment.
Ability to fill small pores.
b) Lanxide Ability to produce complex Slow reaction and growth Graphite Alumina 800-1200°C
shapes. kinetics. Nicalon AlN 800-1200°C
Properties dominated by Long processing time & TiN 800-1200°C
ceramic. high temp. limits chemistry. ZrN 800-1200°C
Very pore grain boundaries. Wetting and reaction are
Systems include: AlN/Al, limitations
TiN/Ti, ZrN/Zr.
[1] Temperature limit depends on fibre. Currently all systems are limited to ≈ 1200°C available fibres.
Ceramic and metal matrix composites: route and properties xlix

CONCLUSIONS

There are four recurring principles that will shape the future of advanced materials:
systems solutions, economical manufacturing processing, diverse markets and new
technologies.
Systems solutions
The industry must drive systems solutions for even the most down-to-earth markets. For
maximum return, development of composite systems must be approached as an integrated
process. Decisions regarding designs, processes and materials must be made synergistically to
ensure peak product performance.
Economical manufacturing processes
For composite material systems to grow successfully in the next century, manufacturing
process must be made more economical, productive and efficient. Efforts in this area are
already under way.
Composite technology has now matured to the point where larger and more complex
structures can be produced with predictable, reliable mechanical properties. The next logical
step in the evolution of this technology is toward thin, complex sections with forming, joining
and inspection all being carried out simultaneously [18]. This will demonstrate the potential
of this technology to dramatically streamline and simplify the manufacture of complex
composite structures.
Diverse markets
To obtain the best return on technology investment, systems solutions and more economical
processes must be applied to new and diverse markets. There are many applications where
existing technology might be successfully applied to commercial markets. It is foreseen that
in the next two decades airframe and engine materials will change from monolithic, metal-
base alloy to ceramic, both monolithic and composite.
New technologies
The final key to success for advanced materials will involve taking experience from both
military and commercial applications and seeking out new technologies that are appropriate to
the future of the industry. The challenge is to identify and focus on the right problems and
opportunities that will facilitate a successful shift from basic science to functioning
technologies.
The procedures for materials selection and bounding of composite properties using selection
charts and merit indices provide powerful general tools for matching materials to the needs of
a design. Implementation of the approach in software greatly facilitates these procedures. The
methodology gives:
1. quick, visually straightforward methods of exploring the potential of a new material for a
given application
2. vectors for the development of new materials to meet a specific design need.
To successfully drive all four principles – systems solutions, economical manufacturing
processes, diverse markets and new technologies – active cooperation is need among industry,
government and academia. It is a formidable challenge, but the stakes are enormous and well
worth the effort.
The future provides the opportunity for growth to a new and healthier balance, with vibrant
commercial sector delivering an improved quality of life and stronger technology base
possessing the agility and responsiveness to support both commercial and national defence
needs.
l M. Rosso

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