Skip to main content
SpringerLink
Log in

Synthesis and Microstructural Development of Particulate Reinforced Metal-Matrix Composites Using the Technique of Spray Atomization and Deposition

  • Conference paper
  • First Online:
Metal-Matrix Composites Innovations, Advances and Applications (TMS 2018)

Part of the book series: The Minerals, Metals & Materials Series ((MMMS))

Included in the following conference series:

Abstract

In this paper, the synthesis of discontinuously-reinforced metal matrix composites using the technique of spray atomization and co-deposition is presented and briefly discussed. This technical manuscript provides a lucid overview of the salient features of the technique of spray atomization and deposition. An attempt is made to highlight the key attributes specific to the processing technique with specific reference to pre-mixed metal matrix composites. The key factors and viable mechanisms governing incorporation of the reinforcing phase during co-deposition is presented and adequately discussed. The microstructure of few composites synthesized by this technique and the key and observable features are briefly highlighted considering the conjoint and mutually interactive influences of processing variables and constituents of the metal-matrix composite.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Log in via an institution
Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 89.00
Price excludes VAT (USA)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Softcover Book
USD 119.99
Price excludes VAT (USA)
  • Compact, lightweight edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info
Hardcover Book
USD 169.99
Price excludes VAT (USA)
  • Durable hardcover edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

References

  1. Koss DA, Copley SM (1971) Thermally-induced residual stresses in eutectic composites. Metall Trans 2A, 1557–1560

    Google Scholar 

  2. Brown LM, Stobbs WM (1971) The work hardening of copper-silica. The Philos Mag: J Theoret, Exp Appl Phys, 23(185)

    Google Scholar 

  3. Divecha AP, Crowe CR, Fishman SG (1977) Failure modes in composites IV. Metallurgical Society of AIME, Warrendale, PA, pp 406–411

    Google Scholar 

  4. Divecha AP, Fishman SG, Karmarkar SD (1981) Silicon carbide reinforced aluminum: a formidable composite. J Metals 33(9):12

    Google Scholar 

  5. Nair SV, Tien JK, Bates RC (1985) SiC reinforced aluminium metal matrix composites. Int Metals Rev 30(6):285–296

    Google Scholar 

  6. Metal matrix composites overview: paper number MMCIAC no. 253, Santa Barbara, California, USA

    Google Scholar 

  7. Schoutens JE (1982) Introduction to metal matrix composites, MMCIAC tutorial series no. 272

    Google Scholar 

  8. Taya M, Arsenault RJ (eds) (1989) Metal matrix composites: thermomechanical behavior. Pergamon Press, New York, USA

    Google Scholar 

  9. Harrigan WC Jr (1991) Metal matrix composites. In: Everett RK, Arsenault RJ (eds) Metal matrix composites: mechanisms and properties. Academic Press, USA, pp 1–15

    Google Scholar 

  10. Lin Yaojun, Zhou Yizhang, Lavernia Enrique J (2004) On the influence of in-situ reactions on grain size during reactive atomization and deposition. Metall Mat Trans 35A:3251–3260

    Article  Google Scholar 

  11. McDaniel DL (1985) Analysis of stress-strain, fracture and ductility behavior of aluminum matrix composites containing discontinuous silicon carbide reinforcement. Metall Trans 16A:1105–1115

    Google Scholar 

  12. Dermarkar S (1986) Met Mater 2:144–147

    Google Scholar 

  13. Chawla KK (1987) Composite materials. Springer, New York

    Book  Google Scholar 

  14. Srivatsan TS, Sudarshan TS (1993) Rapid solidification technology: an engineering guide. Techonomic Publishing Inc., PA, USA, pp 603–700

    Google Scholar 

  15. Hunt WH Jr, Cook CR, Sawtell RR (1991) Cost effective high performance powder metallurgy aluminum matrix composites for aerospace applications, SAE technical paper series 91-0834, Warrendale, PA, USA

    Google Scholar 

  16. Hunt WH Jr (1991) Cost effective high performance composites. In: Presented at international conference on powder metallurgy aerospace materials, Lausanne, Switzerland

    Google Scholar 

  17. Clyne TW, Withers PG (1993) An introduction to metal matrix composites, Cambridge Solid State Science Series, Cambridge University Press, UK

    Google Scholar 

  18. Kreider KG (1974) Metal matrix composites, composite materials, vol 4. Academy Press, New York, p 1

    Google Scholar 

  19. Kelley P (1979) Composites, vol 10, p. 2.t

    Google Scholar 

  20. Srivatsan TS, Sudarshan TS, Lavernia EJ (1995) Processing of discontinuously-reinforced metal matrix composites by Rapid Solidification. Prog Mat Sci 39(4–5):317–409

    Google Scholar 

  21. Fishman SG (1986) J Metals 38(3):26

    Google Scholar 

  22. Flom Y, Arsenault RJ (1986) Mat Sci Eng 77:191

    Google Scholar 

  23. Chou TW, Kelly A, Okura A (1985) Composites 16:187

    Google Scholar 

  24. Piggot MT (1980) Load bearing fiber composites. Pergamon Press, New York

    Google Scholar 

  25. Broutman LJ, Krock RH (1969) Modern composite materials. Addison Wesley Publishing Company, New York

    Google Scholar 

  26. Arsenault RJ (1984) Mat Sci Eng 64:171

    Google Scholar 

  27. Crow CR, Gray RA, Hasson DF (1985) Proceedings of the fifth international conference on composite materials. In: Harrigan WC Jr, Strife J, Dhingra AK (eds) The metallurgical society of AIME, Warrendale, p 843

    Google Scholar 

  28. Ibrahim IA, Mohamad FA, Lavernia EJ (1991) J Mat Sci 26:1137

    Google Scholar 

  29. Crowe CR, Hasson DF (1992) Strength of metals and alloys. In: Gifkins RC (ed) Proceedings of the sixth international conference, Pergamon Press, Australia

    Google Scholar 

  30. Rack HJ (1988) Adv Mat Manuf Process 3(3):327

    Google Scholar 

  31. Srivatsan TS, Ibrahim IA, Mohamad FA, Lavernia EJ (1991) J Mat Sci 27

    Google Scholar 

  32. Davidson DL (1987) Metall Transac 18A:2125

    Google Scholar 

  33. Logsdon WA, Liaw PK (1986) Eng Fract Mech 24:737

    Google Scholar 

  34. Manoharan S, Lewandowski JJ (1990) Acta Metall 328(3):489

    Article  Google Scholar 

  35. Davidson DL (1989) Eng Fract Mech 33(6):965

    Article  Google Scholar 

  36. Davidson DL (1991) The effect of particulate SiC on fatigue crack growth in a cast-extruded aluminum alloy composite. Metall Trans 22A:97

    Article  Google Scholar 

  37. Shang JK, Ritchie RO (1989) Crack bridging by uncracked ligaments during fatigue crack growth in SiC-reinforced aluminum-alloy composites. Metall Trans 20A:897

    Article  Google Scholar 

  38. Singer ARE (1972) J Inst Metals 100:185

    Google Scholar 

  39. Willis J (1988) Metals Mat 4:485

    Google Scholar 

  40. Buhrmaster CL, Clark DE, Smart HO (1988) J Metals 40:44

    Google Scholar 

  41. Kojima KO, Lewis RE, Kaufman MJ (1989). In: Sanders TH Jr, Starke EA Jr (eds) Aluminum-lithium alloys V. MCE Publishers, Birmingham, United Kingdom, p 85

    Google Scholar 

  42. White J, Palmer IG, Hughes IR, Court SA (1989) Aluminum-Lithium Alloys V. In: Sanders TH Jr, Starke EA Jr (eds). MCE Publishers, Birmingham, United Kingdom, p 1635

    Google Scholar 

  43. Llorca J, Ruiz J, Healy JC, Elices M, Beevers CJ (1994) Mat Sci Eng A 185:1

    Google Scholar 

  44. Gupta M, Mohamad FA, Lavernia EJ (1989). In: Mostaphaci H (ed) Proceedings of the 17th international symposium on advances in processing and characterization off ceramic metal matrix composites. Pergamon Press, Oxford, UK, p 236

    Google Scholar 

  45. Gupta M, Mohamad FA, Lavernia EJ (1990) Solidification behavior of Al-Li-SiCp metal matrix composites processed using variable co-deposition of multi-phase materials. Mat Manuf Process 5(2):165–196

    Google Scholar 

  46. Ibrahim IA, Mohamad FA, Lavernia EJ (1991) Particulate-reinforced metal matrix c composites, a review. J Mat Sci 26:1137–1156

    Article  Google Scholar 

  47. Wu Y, Lavernia EJ (1991) Spray atomized and co-deposited 6061 Al/SiCp composites. J Metals 43(8):16–23

    Google Scholar 

  48. Zhang J, Perez RJ, Gupta M, Lavernia EJ (1993) Damping behavior of particulate-reinforced 2519 aluminum metal matrix composites. Scr Metall Mater 28:91–96

    Article  Google Scholar 

  49. Wu Y (1994) Master of science thesis, University of California at Irvine, Irvine, CA

    Google Scholar 

  50. Wu M, Srivatsan TS, Pickens JR, Lavernia EJ (1992) Microstructure and mechanical properties of spray deposited Al-Cu-Li-Ag-Mg-Zr alloy. Scr Metall Mater 27:761–766

    Article  Google Scholar 

  51. Gupta M, Srivatsan TS, Mohamad FA, Lavernia EJ (1993) Microstructural evolution and mechanical properties of SiC/Al2O3 particulate reinforced spray deposited metal matrix composites. J Mat Sci 28:2245–2259

    Article  Google Scholar 

  52. Kim NJ, Park WJ, Ahn S, Elias L (1994). In: Upadhyaya K (ed) High performance metal matrix and ceramic matrix composites. The Minerals, Metals and Materials Society, Warrendale, PA, p 137

    Google Scholar 

  53. Gupta M, Bowo K, Lavernia EJ, Earthman JC (1993) Effect of particulate type on fatigue crack propagation in Al-Li based spray deposited composites. Scr Metall Mater 28:1053–1058

    Article  Google Scholar 

  54. Gupta M, Ibrahim IA, Mohamad FA, Lavernia EJ (1991) J Mat Sci 26:6673

    Google Scholar 

  55. Gupta M, Mohamad FA, Lavernia EJ (1991) The effects of discontinuous reinforcements on the distribution of ceramic reinforcements during spray atomization and co-deposition. Int J Rapid Solidification 6:247–284

    Google Scholar 

  56. Gupta M, Mohamad FA, Lavernia EJ (1992) The effect of ceramic reinforcements during spray atomization and co-deposition of metal matrix composites: part i; heat transfer. Metall Trans A 23A:831–843

    Article  Google Scholar 

  57. Perez RJ, Zhang J, Lavernia EJ (1992) Strain amplitude dependence of 6061 Al MMCs. Scr Metall Mater 27:1111

    Article  Google Scholar 

  58. Zeng X, Lavernia EJ (1992) Interfacial behavior during spray atomization and co-deposition. Int J Rapid Solidification 7:219–243

    Google Scholar 

  59. Wu Y, Lavernia EJ (1992) Interaction mechanisms between ceramic particles and atomized metallic droplets. Metall Trans A 23A:2923–2937

    Article  Google Scholar 

  60. Wu Y, Lavernia EJ (1994). In: Ravi VA, Srivatsan TS, Moore JJ (eds) Processing and fabrication of advanced materials III. The Minerals, Metals and Materials Society Warrendale, PA, p 501

    Google Scholar 

  61. Srivatsan TS, Lavernia EJ (1994) Cyclic strain resistance of a spray atomized and deposited cast aluminum alloy metal matrix composites. Compos Eng Int J 4(4):459–472

    Article  Google Scholar 

  62. Gupta M, Lane C, Lavernia EJ (1992) Microstructure and properties of spray atomized and deposited Al-7Si/SiCp metal matrix composites. Scr Metall Mater 26:825–830

    Article  Google Scholar 

  63. Gupta M, Juarez-Islas J, Frazier WE, Mohamad FA, Lavernia EJ (1992) Microstructure, excess solid solubility and elevated temperature behavior of spray atomized and co-deposited Al-Ti-SiC. Metall Trans B 23B:719–736

    Article  Google Scholar 

  64. Armanie KP, Zaidi MA (1987) Metallographic examination of osprey MMC sample, Technical report, Alcoa Technical Center, Pittsburgh, PA, p 1

    Google Scholar 

  65. Maker PP, Cantor B, Katerman L (1990). In: Kahn T, Effenberg G (eds) International conference on advanced aluminum and magnesium alloys. ASM International, Materials Park Ohio, p 659

    Google Scholar 

  66. Mathur P, Kim MH, Lawley A, Apelian D (1990) Powder metallurgy: key to advanced materials technology. ASM International, Materials Park, Ohio, p 55

    Google Scholar 

  67. Majagi SI, Ranganathan K, Lawley A, Apelian D (1992). In: Lavernia EJ, Gungor MN (eds) Microstructural design by solidification processing. The Minerals, Metals and Materials Society, Warrendale, PA, p 139

    Google Scholar 

  68. Perez JF, Morris F (1994) Scripta Metallurgica Materialia 31:231

    Google Scholar 

  69. Unigame Y, Lawley A, Apelian D (1993) In-situ spray casting of dispersion strengthened alloys I: thermodynamic and reaction kinetics, 1993 powder metallurgy world congress, paper number 14E-T6-6, Kyoto. Japan Powder Metallurgy Association, Japan

    Google Scholar 

  70. Ranganathan K, Lawley A, Apelian D (1993) In situ casting of dispersion strengthened alloys-II, experimental studies, paper number 14E-T6-6, 1993 powder metallurgy world congress, Kyoto. Japan Powder Metallurgy Association, Japan

    Google Scholar 

  71. Zhao YY, Grant PS, Cantor B (1993) J Microsc 169(2):263

    Google Scholar 

  72. Zhao YY, Grant PS, Cantor B (1685) J Physique 3:1685

    Google Scholar 

  73. Baskin D, Wolfenstein J, Lavernia EJ (1994) Elevated temperature mechanical behavior of CoSi and particulate reinforced CoSi produced by spray deposition. J Mater Res 9(2):362–371

    Article  Google Scholar 

  74. Jeng YL, Wolfenstein J, Lavernia EJ (1993) Scripta Metallurgica Materialia 28:453

    Google Scholar 

  75. Jeng YL, Lavernia EJ, Wolfenstein J, Bailey DE, Sickinger A (1993) Creep behavior of plasma sprayed SiC reinforced MoSi2. Scr Metall Mater 29:107–111

    Article  Google Scholar 

  76. Zeng X, Liu H, Chu MG, Lavernia EJ (1992) An experimental investigation of reactive spray atomization and deposition processing of Ni3Al/Y2O3 using N2-O2 atomization. Metall Trans A 23A:3394–3399

    Google Scholar 

  77. Liang X, Lavernia EJ (1992) Interface behavior in Ni3Al/TiB2 intermetallic matrix composites. Mat Sci Eng A 153 1–2:654–661

    Google Scholar 

  78. Lawley A, Apelian D (1994) Powder Metall 37:123

    Google Scholar 

  79. Lawrynowicz DE, Lavernia EJ (1994) Spray atomization and deposition processing of fiber-reinforced intermetallic matrix composites. Scr Metall Mater 31(9):1277–1281

    Article  Google Scholar 

  80. Lawrynowicz DE, Lavernia EJ (1995) A review of sensors and techniques used to monitor processing parameters during spray atomization. J Mat Sci 30:1125–1138

    Article  Google Scholar 

  81. Wu Y, Zhang J, Lavernia EJ (1994) Modeling of the incorporation of ceramic particulates in metallic droplets during spray atomization and co-injection. Metall Mat Trans B 25 B:135–147

    Google Scholar 

  82. Ibrahim IA, Mohamed FA, Lavernia EJ (1990). In: Kahn T, Effenberg G (eds) International conference on advanced aluminum and magnesium alloys. ASM International, Materials Park, OHIO, p 745

    Google Scholar 

  83. Lavernia EJ (1991) SAMPE Q 22:2

    Google Scholar 

  84. Zhang J, Perez RJ, Lavernia EJ (1994). In: Chawla KK, Liaw PK, Fishman SG (eds) High performance composites. The Minerals, Metals and Materials Society, Warrendale, PA, USA, p 361

    Google Scholar 

  85. Wu M, Zhang J, Hunt WH Jr, Lewandowski JJ, Lavernia EJ (1996) J Mat Synth Process, 4:127

    Google Scholar 

  86. Singer ARE (1991) Metal matrix composites made by spray forming. Mat Sci Eng 135A:13

    Article  Google Scholar 

  87. Singer ARE, Ozbek S (1985) Metal matrix composites produced by spray deposition. Powder Metall 28(2):72

    Article  Google Scholar 

  88. Leatham AG, Ogilvy A, Elias L (1993) The osprey process: current status and future possibilities. P/M in Aerospace, Defense and Demanding Applications, San Diego, 7–10 Feb 1993

    Google Scholar 

  89. Zeng X, Nutt SR, Lavernia EJ (1995) Microstructural characterization of Ni3Al processing by reactive atomization and deposition. Metall Mat Trans 26A:817–828

    Article  Google Scholar 

  90. Liu H, Rangel RH, Lavernia EJ (1995) Modeling of molten droplet impingement on a non-flat surface. Acta Metall Mater 43(5):2053–2072

    Article  Google Scholar 

  91. Lee AK, Sanchez-Caldera LE, Chun JH, Suh NP (1989). In: McCandish LE (ed) Multicomponent ultrafine microstructures, MRS conference series. Metals Research Society, Pittsburgh, PA, vol 1342, p 87

    Google Scholar 

  92. Liu H, Zeng ZX, Lavernia EJ (1993) Processing maps for reactive atomization and development processing. Scr Metall Mater 29:1341–1344

    Article  Google Scholar 

  93. Majagi SI, Ranganathan K, Lawley A, Apelian D (1992) In-Situ spray forming of metal matrix composites, in Proceedings of IRC 92: Processing. In: Loretto MH, Beevers CJ (eds) Properties and Application of Metallic and Ceramic Materials, vol 1. MCE Publishers Ltd, Birmingham, UK, pp 135–140

    Google Scholar 

  94. Mutasim ZZ, Smith RW (1992). In: Bernecki TF (ed) Thermal spray coatings: properties, processes and applications. ASM International, Materials Park, Ohio, USA, p 273

    Google Scholar 

  95. Tiwari R, Boulos MI, Jiang XL, Gitzhofer F (1994) Reactive plasma spray of refractory composites, presented at thermal spray synthesis of composites, 1994 materials week. ASM International, Materials Park, Ohio, USA, Chicago, Illinois

    Google Scholar 

  96. Castro RG (1994) Molybdenum disilicide composites produced by plasma spray forming, a presentation at the symposium on thermal spray synthesis of composites, materials week, Chicago, Illinois, USA

    Google Scholar 

  97. Lawrynowicz DE, Wolfenstine J, Nutt SR, Hurt AM, Lavernia EJ (1995) Reactive synthesis and characterization of MoSi2/SiC using low pressure plasma deposition and methane. Scr Metall Mater 32(5):689–693

    Article  Google Scholar 

  98. Smith RW (1993) Powder Metall Int 25:9

    Google Scholar 

  99. Kacar AS, Rana F, DM Stefanescu (1991) Mat Sci Eng A 135:95

    Google Scholar 

  100. Rohatgi PK, Asthana R, Yadav RN, Ray S (1990) Metall Trans A 21A:2073

    Google Scholar 

  101. Ayers JD (1984) Wear 97:249

    Google Scholar 

  102. Ayers JD, Schaefer RJ, Robey WP (1981) J Metals 33(8):19

    Google Scholar 

  103. Ayers JD, Bolster RN (1984) Wear 93:193

    Google Scholar 

  104. Rohatgi PK, Asthana R, Das S (1986) Int Metals Rev 31:115

    Google Scholar 

  105. Tiwari R, Herman H (1991) Scripts Metallurgica Materialia 25:1103

    Google Scholar 

  106. Gupta M, Mohamed FA, Lavernia EJ (1991) Heat transfer mechanisms and their effects on microstructure during spray atomization and co-deposition of metal matrix composites. Mater Sci Eng, A 144(1–2):99–110

    Article  Google Scholar 

  107. Perez RJ, Zhang J, Gungor MN, Lavernia EJ (1993) Damping behavior of 6061 Al/graphite MMCs. Metall Trans A 24A:701–712

    Article  Google Scholar 

  108. Maher PP, Grant PS, Cantor B, Katerman L (1990) Manufacture of spray formed aluminum-based alloys and composites, ICSF 90, p 31

    Google Scholar 

  109. Lee DJ, Vaudin MD, Handwerker CA, Katter UR (1988) Mat Res Symp Proc 120:293

    Google Scholar 

  110. Lo SH, Dionne S, Carpenter G, Zimcik D (1989). In: Lin RY, Arsenault RJ, Martin GP, Fishman SG (eds) Interfaces in metal matrix composites. The Minerals, Metals and Materials Society, Warrendale, PA, p 1675

    Google Scholar 

  111. Carpenter GJC, Lo SH (1992) J Mat Sci 27:1827

    Google Scholar 

  112. Lin Yaojun, Zhou Yizhang, Lavernia Enrique J (2004) Microstructural characterization of oxides in 5083 Al synthesized by reactive atomization and deposition. J Mater Res 19(10):3090–3099

    Article  Google Scholar 

  113. Lin Y, Zhou Y, Lavernia EJ (2004) An analytical model for the oxide size in Al alloys synthesized by reactive atomization and deposition. Metall Mat Trans 35A:3265–3275

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. The University of Akron, Akron, OH, 44325-2903, USA

    T. S. Srivatsan

  2. Chemical Engineering and Materials Science, University of California, Irvine, 509 Aldrich Hall, Irvine, CA, 92697-1000, USA

    Yaojun Lin, Fei Chen & Enrique J. Lavernia

  3. Department of Mechanical Engineering, The University of Akron, Akron, OH, 44325-2903, USA

    K. Manigandan

Authors
  1. T. S. Srivatsan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yaojun Lin
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Fei Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. K. Manigandan
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Enrique J. Lavernia
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to T. S. Srivatsan .

Editor information

Editors and Affiliations

  1. The University of Akron, Akron, Ohio, USA

    T. S. Srivatsan

  2. Gamma Alloys, Valencia, California, USA

    Yuzheng Zhang

  3. Gamma Technology, Valencia, California, USA

    William C. Harrigan, Jr.

Rights and permissions

Reprints and permissions

Copyright information

© 2018 The Minerals, Metals & Materials Society

About this paper

Check for updates. Verify currency and authenticity via CrossMark

Cite this paper

Srivatsan, T.S., Lin, Y., Chen, F., Manigandan, K., Lavernia, E.J. (2018). Synthesis and Microstructural Development of Particulate Reinforced Metal-Matrix Composites Using the Technique of Spray Atomization and Deposition. In: Srivatsan, T., Zhang, Y., Harrigan, Jr., W. (eds) Metal-Matrix Composites Innovations, Advances and Applications . TMS 2018. The Minerals, Metals & Materials Series. Springer, Cham. https://doi.org/10.1007/978-3-319-72853-7_11

Download citation

Publish with us

Policies and ethics

Search

Navigation