Nano and hybrid aluminum based metal matrixcomposites: an overview

Aniruddha V. Muley1,*, S. Aravindan2, and I.P. Singh2

1 Netaji Subhas Institute of Technology (NSIT), Dwarka, New Delhi 110078, India2 Indian Institute of Technology Delhi, Hauz Khas, New Delhi 110016, India

Received 9 June 2015 / Accepted 12 July 2015

Abstract – Aluminium matrix composites (AMCs) are potential light weight engineering materials with excellentproperties. AMCs find application in many areas including automobile, mining, aerospace and defence, etc. Dueto technological advancements, it is possible to use nano sized reinforcement in Al matrix. Nano sized reinforcementsenhance the properties of Al matrix compared to micro sized reinforcements. Hybrid reinforcement imbibe superiorproperties to aluminium matrix composites as compared with Al composites having single reinforcement. This paperis focused on overview of development in the field of Al based metal matrix with nano and hybrid aluminium basedcomposites.

Key words: Aluminium, Nano, Hybrid, Composites

1. Introduction

In quest to realize advance turbine or aircraft design, thetechnological development in the field of composite materialsprovide an opportunity to make a reality. The composite mate-rials have potential to cater the limitations associated with con-ventional materials. Composite materials are designed andmanufactured to solve technological problems for variousapplications including automotive components, sports goods,aerospace parts, consumer goods and marine applicationsdue to their performance, advantages and possibility to pro-duce light weight components [1, 2].

Aluminium matrix composites (AMCs) with theirenhanced strength, improved stiffness, reduced density,improved abrasion and wear resistance offer better alternativeto existing materials used for structural, non structural andfunctional applications [3]. Commonly used reinforcement inAMCs are of micro level, however technological advancementin nano sciences makes it possible to use nano sized reinforce-ment in metal matrix composites and these are termed as MetalMatrix Nano Composites (MMNCs). ‘‘Nanocomposites’’ wereproposed by Choi and Awaji [4], a new material design conceptwhere in second phase nano particles dispersed in matrix toenhance various properties of composite materials. InMMNCs, the reinforcement is in the nanometer range(10�9 m) i.e. less than 100 nm which has interaction at

interface due to its increased surface area, this leads to superiormaterial properties. Nano sized reinforcements can signifi-cantly improve mechanical strength, creep resistance at ele-vated temperature, better machinability and higher fatiguelife without affecting ductility. Improvement in the propertiesof MMCs is attributed to the hardening mechanism, fine parti-cle size, uniform distribution, inter particle spacing and ther-mal stability at high temperature [5–7].

Hybrid composites can have engineering combination oftwo or more forms of reinforcement like fibers, short fibers,particulates, whiskers and nanotubes. It can have differentmaterials as reinforcement like (SiC, Al2O3), (Graphite, SiC)and (Graphite, Al2O3), etc. e.g. Car engine block in whichgraphite and alumina are used in the form of particulates [8–10]. Hybrid metal matrix composites shows improved mechan-ical properties due to reduction in meniscus penetration defectand reduced formation of inter-metallic component at inter-faces because of increased interfacial area [11]. There havebeen a very few studies available on aluminium (Al) basedhybrid composites. A few research studies on Al based hybridcomposites are available in which investigations on reinforcedAl/Al alloys with hybrid composition of Al2O3 fibres + Al2O3

particulates, SiC particles + graphite fibres, Al2O3 fibres +SiC particles, Carbon short fibres + Al2O3 short fibres,ABOw(Al18B4A33) + BPOp(BaPbO3), BPOw + WO3 particles,glass fibres + SiC fibres and ABOw + SiCp were reported[12–16].*e-mail: avmuley2000@yahoo.com

Manufacturing Rev. 2015, 2, 15� A.V. Muley et al., Published by EDP Sciences, 2015DOI: 10.1051/mfreview/2015018

Available online at:http://mfr.edp-open.org

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2. Processing of Al based metal matrix nanoand hybrid composites

Processing of Metal Matrix Composites (MMCs) mainlyclassified into two groups namely ex-situ synthesis and in-situsynthesis. In ex-situ synthesis the particles are added into themetal matrix from outside and in in-situ synthesis the rein-forcement is realized by chemical reaction or exothermic reac-tion e.g. exothermic dispersion, reactive hot pressing, reactiveinfiltration and direct melt reaction [17]. Ex-Situ methods con-sists of solid state processing and liquid state processing. Solidstate includes Powder Metallurgy (PM), Diffusion Bonding,Immersion Plating, Electroplating, Spray Deposition, ChemicalVapour Deposition (CVD), Physical Vapour Deposition (PVD),etc. Liquid state processing includes Stir Casting, Melt Infiltra-tion, Melt oxidation Processing, Squeeze Casting, CompoCasting/Rheo Casting, etc. [18]. Manufacturing processes usedfor MMCs are also suitable for processing Al based nano andhybrid composites. Several researchers have reported the use ofconventional methods such as PM, Stir Casting, Squeeze Cast-ing as well as many other techniques like High Energy BallMilling, Mechanical Alloying, Pressureless Infiltration, GasInjection Spray Forming, Spark Plasma Sintering, UltrasonicCavitations based solidification, Vortex Process, Sol-Gel syn-thesis, Laser Deposition, etc. [19, 20].

Viswanathan et al. [21] have reported on the limitation oftraditional consolidation techniques which are unable to retainthe nano scale grain size owing to the excessive grain growthduring processing. Processing methodologies of nano compos-ites is reviewed in an exhaustive way. The various processingroutes are presented in Table 1.

Figures 1–8 show the schematic diagram of various pro-cesses used in the development of nano composites.

Nano particles have the tendency of agglomeration andclustering, due to high surface energy, attractive Van der-waal’sbonding, electrostatic and moisture adhesiveness, which affectits uniform distribution during processing. Cao et al. [5, 7],Yang et al. [19, 20], Li et al. [22], Sunnel et al. and Dontham-setty et al. [23, 24], Narsimha Murthy et al. [25] and Mirandaet al. [26] used Ultrasonic Cavitations based method to fabri-cate nano composite and reported improvement in uniform dis-tribution of nano particles by avoiding agglomeration andclustering in the matrix material.

Zok et al. [27] used extrusion method for consolidation ofhybrid metal matrix composite Al-SiC rod/Al alloy. Jang et al.[28] used powder metallurgy method to fabricate nano and

hybrid composite and reported that the surface properties,changes of nano materials and high aspect ratio up to 1,000causes clusters of individual fiber into agglomerates.

Table 1. Advanced processing techniques of nano composites [21].

Mechanical processing Thermo-mechanical processing Non-equilibrium processing Room temperature processing

(a) Severe plastic deformation(b) Equal angular processing(c) High pressure torsion(d) Shock wave consolidation(e) Transformation assisted

consolidation

(a) Hot pressing(b) Hot isostatic pressing(c) Hot extrusion(d) Sintering(e) Sinter forging

(a) Microwave sintering(b) Thermal spray processing(c) Plasma spraying(d) High velocity Oxyfuel spraying(e) Cold spraying(f) Spark plasma sintering(g) Laser based techniques

(a) Electro deposition(b) Nano consolidation of self

deposition structures

Figure 1. Schematic of equal-channel angular pressing process.ø and W are the channel intersection angle and the arc curvatureangle [21].

Figure 2. Schematic of high pressure torsion [21].

2 A.V. Muley et al.: Manufacturing Rev. 2015, 2, 15

Low power sonication had been used to disperse nano sizedfibrous material ultrasonically. Mula et al. [29] used non con-tact ultrasonic casting method for 2 wt.% Al2O3/Al nano com-posite which resulted in improved mechanical propertiesbecause of uniform dispersion of nano Al2O3 particles. Figure 9shows the application of ultrasonic energy to have uniform dis-persion of nano reinforcement in aluminium matrix.

Lin et al. [30] used mechanical milling and hot pressing tofabricate Al based nano composite in the form of large billetsbut this process produces non uniform, bimodal grain size dis-tribution due to the re-crystallization and grain coarsening atelevated temperature. Liu et al. [31] have employed an in-situ

method which uses high pressure to consolidate the nano SiC/Al composite. It was reported that due to large surface area tovolume ratio of nano scale reinforcement chemical reactionand diffusion occur easily; hence this method produce wellbonded nano composite, but agglomeration could not beavoided completely. Torralba et al. [32] reviewed PM tech-nique for Al matrix composite and have reported the advanta-ges of PM method as low temperature manufacturing whichnot only avoids strong interfacial reaction but also minimizeundesired reaction between Al matrix and reinforcement. PMroute also makes it possible to produce MMCs which are notpossible by other method e.g. SiC/Ti alloy composites. Wooand Zhang [33] have reported use of high energy ball millingand powder metallurgy method to produce Al based nano com-posites. Eutectic reaction occurred during milling increases thesintering rate due to increased diffusion rate for the compositepowder which in turn gives finer microstructure, high hardnessand less pores. Zhang et al. [10], Sureshbabu et al. [11], Fenget al. [12] and Geng et al. [34] have used squeeze casting tofabricate Al based hybrid composite which distribute nano par-ticles homogeneously that increased strength and resistance tofracture propagation. Reddy et al. [35] produced aluminiummatrix hybrid (Al3Ni/Al2O3) nano composite by mechanicallyactivated solid state combustion in-situ method without affect-ing nano-structure. It was reported that in-situ processed com-posite are technologically considered to be more advancedcomposites than ex-situ processed composite materials. Physi-cal state of reactant phase form the basis for grouping in-situmethods such as liquid-liquid, liquid-solid and solid-solid reac-tions e.g. Direct Melt Oxidation (DIMOX), Exothermic Dis-persion (XD) and Self Propagating High TemperatureSynthesis (SHS). Bustamante et al. [36] have producedmulti-walled carbon nano tube (MWCNTs) reinforced Almatrix nano composite by mechanical milling followed bypressureless sintering at 823 K under vacuum. No damageoccurred to multi-walled carbon nano tube during processing.Milling time vol.% of MWCNTs reinforcement influencedmechanical properties of nano composites. Laha et al. [37]have reported on limitation of processing of carbon nano tube(CNTs) reinforced metal matrix bulk nanocomposite. Incorpo-rating CNTs in MMCs is a difficult task and it is further diffi-cult to achieve homogeneous distribution and effectiveretention of CNTs in the matrix after processing. Effectiveinterfacial bonding between matrix and reinforcement is desir-able to transfer load in metal matrix nanocomposite. It is chal-lenging to develop processing techniques for CNTs. CNTsreinforced in Al matrix composites were successfully fabri-cated by Plasma Spray forming and High Velocity Oxy-fuelSpray forming. Both the techniques are capable of producingcomposites with intact and undamaged MWCNTs withimproved properties. Wang et al. [38] have prepared Al matrixcomposite by in-situ Direct Melt Reaction technique. Analysisshowed uniform dispersion of Al2O3 and clean interfacebetween particles and Al matrix. In this process performanceof composite showed improvement as there were large amountof high density dislocations and extensive fine sub-grainsaround Al2O3 particles and no impurity existed between parti-cles and matrix. This composite reported to possess isotropicproperties. Fully dense Al based nano composite by combining

Figure 3. Microwave sintering [64].

Figure 4. Schematic of a hot isostatic pressing setup [59].

A.V. Muley et al.: Manufacturing Rev. 2015, 2, 15 3

two Severe Plastic Deformation (SPD) processes; planetaryball milling for mixing powders and back pressure equal-channel angular pressing for consolidation [39]. Thus producedcarbon nano particles/Al and nano Al2O3/Al composite exhibiteffective particle distribution. Joo et al. [40] have reported useof high pressure torsion (SPD) processing to produce nanotube/Al composites. This has developed homogeneous nanostructures with high angle grain boundaries due to its abilityto impose extremely high strain and hydrostatic pressure.Xue et al. [41] have fabricated diamond + SiC/Al compositewith high volume fraction by gas pressure infiltration. Theresults showed that the fine SiC particles occupy the interstitial

position around course diamond particles. Lee et al. [42] havereported on Friction Stir Processing (FSP) is promising methodto produce Al matrix composite. FSP induce severe plasticdeformation to promote mixing and refining of constituentphases in the material and hot consolidation helps to form fullydense solid. It is a versatile technique which helps to controlthe microstructure and mechanical properties by optimizingthe tool design and FSP parameters. Nandpati et al. [43] haveused friction stir welding process (FSWP) to produce nano SiCreinforced AA6061 composite. The low weldability of Alrestrict the use of fusion welding method to weld parts usedin aircrafts and other applications. This technique has signifi-cant potential to join Al alloys and composites with highstrength joints.

Wong et al. [8], Gupta et al. [44] have reported successfulsynthesis of hybrid composite (Al/Fe + SiC and Al/Fe + Tirespectively) by using Disintegrated Melt Deposition (DMD)followed by hot extrusion. This method has produced compos-ite with uniform distribution with good interfacial integritybetween reinforcement and matrix and absence of reactionproduct at the iron wire/Al interface. Reddy et al. [45] have

Figure 5. Schematic of sinter forging process [60].

Figure 6. Schematic of plasma spraying operation [61].

Figure 7. Schematic of high velocity oxy-fuel spraying [62].

4 A.V. Muley et al.: Manufacturing Rev. 2015, 2, 15

used microwave processing to fabricate hybrid metal matrixcomposite for electrical sliding contact application. Microwavesintered metal matrix composite revealed higher relative den-sity and hardness compared to traditionally sintered compos-ites. Microwave sintering is potentially better method toproduce composites.

Thakur et al. [46] have manufactured Al/SiC nano compos-ite by using energy efficient microwave assisted powder metal-lurgy route. Use of PM coupled with hybrid microwavesintering and hot extrusion resulted in uniform distribution ofnano sized SiC particles, but some minor clustering and min-imal porosity occurred.

One of the problem encountered in processing of Al basednano and hybrid composite by liquid state route is settling ofparticles due to density difference between matrix and

reinforcement. Stir Casting method provide solution to avoidsettling of particles.

Rajan et al. [47], Ramesh et al. [48] have used Stir Castingmethod to produce Al based composites. Schultz et al. [49]have fabricated nano Al2O3/Al-Mg alloy composite by stircasting method. It was reported that conventional stir mixingfollowed by casting is one of the most economical techniquesavailable to produce MMCs. Nano sized reinforcement ofinterest are not wet by molten metal during stir mixing andnano particles have tendency to cluster, but reactive wettingcombined with high shear stir mixing has the potential to over-come this problem. Hashmi et al. [50] have discussed the useof stir casting method to produce MMCs and difficulties asso-ciated with getting a uniform distribution, good wettability andlow porosity. The stir casting method is cost effective, simpleand flexible. The method can handle large quantity of produc-tion, minimizes the final cost of product and allows large sizedcomponents to be fabricated.

Kumar and Kruth [51] have focussed on application ori-ented composites and very new idea of using rapid prototyping(RP) technology to produce composites. Out of various tech-niques available only some have been used for fabricatingcomposite like Selective Laser Sintering/Melting (SLS/SLM),Laser Engineered Net Shaping (LENS), Laminated ObjectManufacturing (LOM), Stereo Lithography (SL), Fuse Deposi-tion Modelling (FDM), 3D Printing (3DP) and Ultrasonic Con-solidation. Rapid Prototyping initially used for polymericcomposites but it can be used to produce parts made of metalmatrix composites. It was reported that SLS has potential toproduce MMCs and nano composites. Li et al. [65] have suc-cessfully used AC pulse electro deposition method to fabricateNi/GO nanocomposites. The nanocomposites producedreported have enhanced plasticity.

The second secondary processing of AMCs furtherimproves their performance. Hot extrusion is secondary form-ing process often used to improve properties of AMCs forindustrial applications. It enhances the UTS and % elongationof Al matrix composites compared to as-cast compositesmainly due to decreasing the amount of porosity. It is reportedto that with extrusion ratio of 18:1 at 420 �C gives optimumvalue for UTS and elongation of Al composites [66]. Hotextrusion helps to disperse the reinforcement homogeneouslyin Al matrix and also gives final size of Al grain considerablyfine. In as-cast aluminium matrix composites poor restrict theirproperties and applications. The ductility of AMCs affected byparameters like microstructure, distribution of reinforcementsand porosity. To improve ductility secondary processing ofthe discontinuously reinforced AMCs become essential. Hotextrusion is better method to for this purpose which helps inbreaking particle agglomerates, distributing particles homoge-neously, reducing porosity, improving particle matrix bondingand refining matrix structure. This can results in bettermechanical properties compared to as-cast composites [67].

The overview of the different manufacturing methods showthat there is a need to find, select and decide on the use of themost suitable manufacturing method to process Al based nanoand hybrid composites. The manufacturing process that givesuniform distribution of nano particles/hybrid reinforcementwithout clustering and agglomeration as well as without

Figure 8. Schematic of spark plasma sintering setup [63].

Figure 9. Ultrasonic cavitations based nano composite manufac-turing set up [19].

A.V. Muley et al.: Manufacturing Rev. 2015, 2, 15 5

damaging particles is preferred. The process should producethe composite which has better interfacial bonding, better wet-tability, non reactive and clean interface. The selection of suit-able manufacturing method for MMCs based on ability toproduce fine grain, reduced grain growth, ability to producenear net shapes and low temperature of processing. The effec-tive parameter control, optimized parameters, and ability toprocess large volume fraction of reinforcement are the factorsthat affect the decision on selection of manufacturing method.The other factors such as superior mechanical properties, lowthermal expansion, ability to handle large production rate, abil-ity to produce large sized parts, safety of production and com-mercial viability, are required to be considered while selectingthe manufacturing process.

3. Properties of Al based metal matrix nanocomposites

Prime objective of manufacturing and using compositematerials is that their properties can be tailored by varyingthe nature of the constituents, their volume fraction and pro-cessing routes. Al matrix composite refers to the class of lightmaterials having superior combination of properties such ashigh strength, high stiffness, low density, improved elevatedtemperature properties, etc. AMCs can pose tough competitionto existing monolithic, materials and offer strong alternative asmaterial to be used in engineering applications.

Commonly used ceramic reinforcement such as SiC andAl2O3 affect the physical, mechanical, thermo-mechanicaland tribological properties of AMCs. AMCs have bettermechanical properties over unreinforced Al/Al alloy due tochange in matrix microstructure [3, 52].

With the invent of nano sized reinforcement (CNTs, nanoparticles, etc.), it can be used in Al matrix composites due tophenomenal properties which they exhibit. Nano sized rein-forcement have superior properties. e.g. CNTs have stiffnessof about 1,000 GPa, strength 100 GPa and thermal conductiv-ity 6,000 W/m K depending on its structure. It was shown thatwith the addition of small wt.% (0.05 wt.% and 0.1 wt.%) ofCNTs in LM24 Ultimate Tensile Strength (UTS) was reportedto be increased by 8% and yield strength increased by 32%with corresponding decrease in elongation by 16%. This hashappened because of CNTs pinning and hindering both grainboundaries and dislocation migration during applied load.The results obtained were in the line with the expectation thatsmall grain size would result in a larger yield strength andlower elongation in accordance with Hall-Petch criteria [26].

Milling time and volume fraction of MWNCTs have animportant effect on the mechanical properties of Al based nanocomposites. With increase in milling time from 0 to 1 h andMWCNTs volume fraction from 0 to 0.75%, yield strengthincreased upto 300% compared to sample without MWNCTsand unmilled. Hardness of the composite is also increased withincrease in MWNCTs reaching the maximum value of around77 Hv with 2 h of milling time and 0.75 vol.% of reinforce-ment [36].

The hypothesis for strengthening mechanism of MWCNTsreinforced nanocomposite consist of four points (a) Obstruc-tion of dislocation motion by MWNCTs; (b) Wetting ofMWNCTs by Al matrix; (c) Thermal mismatch betweenMWNCTs and Al matrix; (d) Formation of a transition layerbetween the MWNCTs core and the Al matrix. TEM observa-tion confirms the absence of dislocation within the nanocom-posite. Wetting is the necessary condition for interfacialshear transfer however wetting is not possible due to large dif-ference in surface energies of Al matrix and MWCNTs anddifference in surface tension values. The surface tension of alu-minium is 865 N/m and MWNCTs 100–200 N/m. The volumecontraction of Al after heat treatment may contribute to themechanical adhesion of the MWNCT to matrix. TEM observa-tion showed the formation of transition layer seems to be veryrough. MWNCTs are immersed in the Al matrix and theroughness being the source of stress transfer between Al matrixand MWNCT. Further additional work is required to under-stand the strengthening mechanism operating in the Al basedcomposite. No literature is available on the wetting phenomenaand interfacial properties of Al-CNT system [36, 37, 40].

Aluminium reinforced with nano sized SiC particles withvarying vol.% (5 vol.%, 10 vol.% and 20 vol.%) increasedthe micro-hardness of the composites. It is evident that theincrease in volume fraction of SiC particles have resulted intohigher micro-hardness of composite. The increase in hardnessis attributed to the use of high temperature and pressure whichin turn enhanced adhesion between Al matrix and SiC nanoreinforcement. At high temperature SiC/Al interface becomereactive which produces aluminium carbide Al4C3 and Si.The excess Si harden the Al matrix [30]. Al/SiC system is stud-ied by many researchers extensively because of their compati-bility with each other. Most of the reported research work onAl/SiC showed use of micron sized particles as reinforcement.Due to technological development use of nano SiC as rein-forcement generated interest among researchers. Addition ofSiC in Al matrix improves its mechanical properties consider-ably. It was reported that on 2 wt.% of nano sized SiC in A356matrix improved its yield strength by 50% which is signifi-cantly better than Al alloy with same percent of micro particlereinforcement [47]. But very little work done so far on this sys-tem of nano composite.

Fly ash from thermal power plant is also used as nano rein-forcement in Al alloy matrix to enhance mechanical properties.The use of nano sized fly ash particles (1 wt.% to 3 wt.%)increased hardness of AA2024 from 75 Hv for 1 wt.% to114 Hv for 3 wt.%. Presence of harder fly ash nanoparticles,higher constraint to the localized matrix deformation duringindentation, harder CuAl2 phase in the matrix and refined grainstructure of matrix attributed to increase in hardness. Further-more cooling of composite after processing to room tempera-ture; mismatch strain due to the difference of coefficient ofthermal expansions between the nano fly ash reinforcementand Al matrix develop high density dislocations whichstrengthens the matrix. Nano fly ash obstruct the movementof high density dislocations resulting in improvement of hard-ness. Compressive strength of nano fly ash/Al composite

6 A.V. Muley et al.: Manufacturing Rev. 2015, 2, 15

increased with increase in wt.% of nano fly ash. The strengthof AA2024 alloy is 289 Mpa and it is increased to 345 MPafor 3 wt.% fly ash/AA2024 composite. The transfer of loadfrom matrix to the particulate, the interaction between nanosized particulates and individual dislocations, reduction inmatrix grain size and generation of high density dislocationsin the matrix are reasons for increased compressivestrength [25].

There are two reasons to dislocation pile up; grain bound-aries and formation of grain boundary ledges because of multiglide plane agglomeration. Under the applied stress multi-glid-ing system due to induced multi directional thermal stressesduring processing develop dislocations in several directions.The increasing amount of grain boundaries and grain boundaryledges act as obstacle to dislocation movement to increasestrength of composite [25, 38]. Figure 10 shows TEM of Alalloy/Al2O3 nano composites [58].

Graphene is one atomic layer thick sheet of carbon. It hastwo dimensional honey comb structure. Graphene has remark-able thermal (Thermal conductivity – 5.3 · 103 W/mK), elec-trical and mechanical (Intrinsic Strength 130 GPa, Young’sModulus – 1.0 TPa) properties which makes it a superior mate-rial for reinforcement in AMCs. Due to graphene’s excellentproperties it has ability to replace CNTs as a first choice forreinforcement in nanocomposite materials. Graphene has manyadvantages over CNTs like higher specific surface area(2,600 m2/g), has less tendency to twist, ability to disperse inmatrix easily, higher strength and stiffness [68–70]. Graphenehas fracture strength of 125 GPa which makes it an ideal mate-rial for reinforcement in AMCs. It has been reported that withonly 0.3 wt.% of GNS (Graphenes Nano Sheets) the tensilestrength of AMCs enhanced by 62% compared to unreinforcedaluminium matrix [71].

4. Properties of Al based metal matrix hybridcomposites

Reinforcement in hybrid form to improve properties ofcomposites, which gives high degree of freedom in material

design. The properties of hybrid composites are more excellentthan those composites with single reinforcement due to hybrideffectiveness produced by combination of reinforcement inhybrid composite. Al matrix composite when reinforced withhybrid combination of SiC and Graphite particulates produceexcellent mechanical and tribological properties. SiC in Almatrix helps in strengthening and graphite reinforcement aidsin lubrication. But SiC causes ductility of composite todecrease and graphite decrease whole mechanical capabilityof composite. Heat treatment at 630 �C of Al/SiC + Gr com-posite improve its hardness as a result of interfacial reactionat matrix and reinforcement interface with the formation ofreaction product Al4C3 [9].

The addition of SiC whiskers is more effective in improv-ing the strength and ductility of composites than addition ofSiC particulates. The investigations on SiC reinforcement havefound that particle size less than 10 lm gives better mechani-cal properties. Hence hybridization of SiCw + SiC nano partic-ulates can further enhance properties of composites [10].

Though Aluminium borate whiskers ABOw (Al18B4A33)are of low cost they possess superior stiffness and strength.ABOw reinforced Al matrix composite can be easily formedand machined by conventional techniques. These compositesfind applications in many fields such as automobile shaft andbrake rotors. WO3 (Tungsten Oxide) is used in functional mate-rials, hard alloy and radiation protection materials. To exploitthe advantages of these materials, as reinforcement in compos-ites, the fabrication of Al/ABOw + WO3 hybrid composite isreported for the protection of semiconductor devices forX-ray. It was reported that elastic modulus, UTS and yieldstrength increased from 69 GPa to 96 GPa, 47 MPa to287 MPa and 24.27 to 250 MPa respectively than the matrixmaterial. But ductility of hybrid composite decreases and lowerthan the matrix material. However as compared to other com-posites elongation is appreciable. Hybrid composite exhibithigh potential to be used for various applications because ofits superior properties [12].

Another composite for radiation protection applicationreported, was Al/ABOw (Al18B4A33) + BPOp (BaPbO3). Itshowed that BPOp reacts with Aluminium forming a coating

Figure 10. TEM of Aluminum Alloy-Al2O3 nanocomposites produced by liquid and solid based methods respectively. (A) Stir cast A206- 2vol.% Al2O3 (47 nm) nanocomposite. (B) Powder metallurgy based Aluminum alloy-15 vol.% Al2O3 nanocomposite [58].

A.V. Muley et al.: Manufacturing Rev. 2015, 2, 15 7

(100 lm thick) on the surface of ABOw. This coating consistof Ba, Pb and Al. Pb grain size of 30 nm. This hybrid compos-ite have better mechanical properties compared with Al/ABOw

composite. It was reported that tensile strength and young’smodulus of Al/ABOw + BPOp increased to 224 MPa and104 GPa respectively compared to Al (Tensile strength64 MPa and Young’s modulus 69 GPa) and Al/ABOw (Tensilestrength 138 MPa and Young’s modulus 107 GPa). Theincrease in ductility also is reported due to Pb phase [13].

Hybrid composites fabricated using in-situ process mag-neto-chemical reaction between A356-Zr(CO3)2, consist ofAl2O3 + Al3Z2 nano particulates. The particle distribution inthe matrix was uniform. It was indicated that mechanical prop-erties UTS, yield strength and hardness reached to higher val-ues of 393.87 MPa, 339.74 MPa and 139.8 N/mm2

respectively compared to composite obtained without the assis-tance of pulsed magnetic field. The change in elongation isalmost negligible for this hybrid composite [17].

Successful fabrication of hybrid composite which consistof 6,061 Al/5 vol.% ABOw + 15 vol.% of SiCp has reported.For this system of hybrid composite semi solid stirring tech-nique was used. ABOw with a diameter of 5 lm, length 10–30 lm and SiC particles within range of 8–14 lm used. Tensilestrength of hybrid composite fabricated at different stirringtemperature and time were reported. Stirring temperatureselected were 680 �C, 650 �C, 640 �C and 630 �C, and stirringtime 20 min and 30 min. UTS of the composite fabricated at640 �C was 293 MPa, 680 �C – 186 MPa, 650 �C – 251 MPaand 630 �C – 228 MPa. The increase in the UTS for 640 �Cwas 57.5%, 16.7% and 28.5% more compare to UTS at680 �C, 650 �C and 630 �C respectively. The elongation ofcomposite fabricated at 640 �C – 4.6% was higher by 50%,23.9% and 30.4% than composite at 680 �C – 2.3%, 650 �C– 3.5% and 630 �C – 3.2% respectively. Increase in stirringtime significantly increase UTS and elongation. At stirringtime 20 min UTS- 214 MPa and elongation 2.5%, for 30 minstirring UTS 293 MPa and elongation 4.6% werereported [16].

In 2024 Al matrix, reinforced with SiCw and SiCp, hybridcomposite SiCp leads to increase in the wear resistance, elasticmodulus and in CTE (coefficient of thermal expansion) whileSiCw improves strength and ductility. It was observed thathybrid composite showed increasing trend in UTS and elasticmodulus at the same time trend in % elongation decreasingfor increasing SiCp wt.% (2%, 5% and 7%) at 20 wt.% SiCw

[34].

5. Applications of Al based metal matrix nanoand hybrid composites

There is huge potential for use of Al based metal matrixcomposite due to the superior properties and high degree oftailorability that they confers. It is seen that by using nanosized particulates as reinforcement as well as hybridizationof reinforcement one can tailor and provide excellent proper-ties to Al based composites compared to Al based alloy andmicron sized singly reinforcement reinforced Al based com-posites. Various functionalities could be designed through

appropriate selection of constituents in Al based hybrid andnano composites.

5.1. Structural applications

Strength and stiffness are the two most important chal-lenges for structural applications. Al based composites providecompetitive level of specific strength and stiffness. In additionto excellent specific stiffness and strength, structural applica-tion requirements are high bearing strength, resistance toaggressive environments, resistance to out gassing, goodthrough thickness thermal conductivity, good wear resistance,high dimensional stability, good impact and erosion resistance,resistance to burning and high temperature application. Albased composites provide better response in these areas. Theuse of Al based composite in fracture critical application pro-vides sufficient evidence for the same e.g. tyre stud, drive shaftin Chevrolet S-10. Improved properties can be achieved withmore uniform distribution and finer particulate sizes [53].

5.2. Thermal applications

High thermal conductivity, specific thermal conductivityand CTE (coefficient of thermal expansion) are importantproperties for thermal applications like substrates for computerprocessor chips, power semiconductor devices used in telecom-munications, sub components in aerospace system and auto-motive applications. Al based composites can be useful forthese applications e.g. Al/SiC composite used for satellitemicrowave system, flip chip lid in networking and telecommu-nication and, intake and exhaust valve in Toyota Altezza [53].Development of Al based hybrid composites for high temper-ature application reported, have SiC, Al2O3 and TiB2 as rein-forcements [54]. Nano sized SiC reinforced in aluminiumexhibit better dimensional stability, hence can be used for ther-mal applications that requires high dimensional stability [55].

5.3. Precision applications

Many precision applications require exceptional resistanceto distortion that occurs due to thermal and mechanical loadsuch as hard disk drive, video recording head, atomic forcemicroscope support frame, robotic arms, satellite antennaeand high speed manufacturing equipments. Al based compositeprovide improved resistance to this requirements e.g. spaceshuttle mid fuselage main frame, Hubble space telescopeantenna [53].

5.4. Wear resistance

Wear resistance is an important requirement for Al basedcomposite for many applications such as piston and cylinderbore in engine, especially brake system (disk, rotors, padsand callipers) in automotive area. Al based composite offerhigh thermal conductivity, good wear resistance, reduced brak-ing noise, low density for fuel economy, better acceleration andreduced braking distance. Al/SiC composite used for the rearbrake drums of Volkswagen Lipo 3L and the Audi A2.

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Table 2. Properties of Al based metal matrix nano and hybrid composites.

Material Particle size (lm/nm) Vol.%/Wt.% Elastic modulusGPa

UTS MPa Yield strengthMPa

%Elongation

Hardness Ref.

Al/SiC + Gr 20 wt.%, 6 wt.% 153 [9]2024Al alloy/SiCw +

SiCp

0.3–0.6 lm, 10–28 lmlength 35 nm

20 vol.%, 0–7 vol.% 150–200 450–600 275–550 [10]

Pure Al/WO3p + ABOw 18 lm 0.5–1 lm, 10–30 lmlength

3 vol.%, 22 vol.% 96 287.30 250.7 1.66 [12]

Pure Al/ABOw + BPOp 0.5–1 lm, 10–30 lmlength 0.2–0.5 lm

20 vol.%, 5 vol.% 104 224 3.5 [13]

Pure Al/ABOw 0.5–1 lm, 10–30 lmlength

20 vol.% 107 138 0.48 [13]

PureAl/WO3p + ABOw 3 lm WO3 ABOw [14]0.5–1 lm, 10–30 lm

length3 vol.%, 22 vol.% 280 1.55 vol.%, 20 vol.% 260 1.37 vol.%, 18 vol.% 200 1.0

6061 Al/ABOw + SiCp 0.5–1 lm, 10–30 lmlength

5 vol.% 293 (at 640� C) 4.6 [16]186 (at 680 �C) 2.3251 (at 650�C) 3.5228 (at 630 �C) 3.2

8–14 lm 15 vol.% 293 (at 30 min. stirring) 4.6214 (at 20 min. stirring) 2.5

A356/Al2O3 + Al3Zr 0.08–.13 lm 20 wt.% [17]Without magnetic field

assistance354 278.95 4.85 108 N/mm2

With magnetic fieldassistance

393.87 339.74 4.72 139.8 N/mm2

AA 2024/Fly ash 23 nm 1–3 wt.% 289–345 Compressivestrength

75–114 Hv [25]

LM24/Cu-CNT nano fillers 1–100 lm 0.05–0.1 wt. % 150 4.81 [26]Al/SiC 25 nm 5 vol.%

10 vol.%20 vol.%

90 Hv130 Hv170 Hv

[30]

Al/SiCw + SiCp T6 0.3–0.6 lm, 10–28length 35 nm

20 vol.%, 2–7 vol.% 124–127 513–620 0.77–0.83 [34]

Al/SiCw 0.3–0.6 lm, 10–28length

27 vol.% 126 613 0.8 [34]

Pure Al/MWCNTs 0.25–0.75 vol.% 198.5–330.8 126.1–230.5 57–77 Hv [36]Al/Fe mesh/SiC 25 lm 75.2 214 191 3 [45]Al/Fe mesh 76.7 168 151 4 [45]

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Al/SiC Brake disks in Intercity Express (ICE) high speed trainin Germany [53].

Nano composite with SiC, SiO2, TiO2, BN3 and diamondwithin matrix materials such as Al, Ni and Fe finds applicationin automotive industry and have a striking impact on car bodiesand components [56].

6. Issues and challenges in nano and hybridcomposite

Nano and hybrid composites both have improved proper-ties compared to monolithic materials and single reinforcementmicro particle composites. Though they provide new avenues,there are many issues and challenges to make them useful inengineering applications and commercially viable for widespread choice.

Various issues in nano and hybrid composites are related to(a) fabrication/processing techniques to produce uniform distri-bution of reinforcement in matrix and interfacial bonding,(b) formability due to reduced ductility, (c) improvement inmechanical properties with respect to volume fraction andparticle size; also to understand strengthening mechanismsand role of individual reinforcement in hybrid composites,(d) tribological properties which include wear and friction,(e) use of composite in corrosive media, (f) thermal conductiv-ity, thermal expansion and dimensional stability at hightemperature [55].

Performance of Al based metal matrix composite materialsdepend on volume fraction and particle size. There is a need toimprove and modify existing processing methods to be used infabrication of Al based nano and hybrid composite. Also thereis a need to develop new methods. Formability of Al based metalmatrix composites is an important issue as addition of reinforce-ment particles reduces the ductility of composites, which makesthem unsuitable for forming. There is need to develop compositewithout affecting its ductility. Weight loss of composite dependsstrongly on volume fraction and particle size. To obtainedimproved mechanical, tribological and other properties for Albased composites, there is need to focus on processing tech-niques, process parameters, process control, handling of largevolume fraction, particle size, interface, method to improve wet-tability and uniform distribution, extreme service condition.There is a need to develop composite without compromisingtoughness, produce reinforcement particles with low cost,improve upon secondary processing techniques for large vol-ume production with low cost, recyclability and commercialviability [57]. Table 2 presents the properties of aluminiumbased metal matrix nano and hybrid composites.

Especially there is need to address environmental and costissues related to aluminium matrix nano and hybrid compos-ites. This issues restrict their wide spread use as alternativelight weight materials. The environmental conditions affectthe performance of Al matrix composites. The corrosionbehaviour of aluminium matrix composite in various environ-ments is an important selection criteria for Al and its alloysas a matrix for particular purpose. Reinforcements (particu-lates and fibers), conditions of processing of AMCs can causeaccelerated corrosion of Al alloys matrix composites as

compared to unreinforced Al alloys. The different forms ofcorrosion associated with Al matrix composites are pitting cor-rosion, galvanic corrosion, crevice corrosion, stress corrosioncracking, corrosion fatigue and tribo corrosion. The primarysources of corrosion for Al matrix composites are galvanic cor-rosion between matrix and reinforcement, chemical degradationof interfaces and reinforcements, corrosion due to processingconditions of Al matrix composites and resulting microstruc-tures. AMCs with corrosion resistance can be produced by con-trolling microstructures of composites, processing conditionsand interaction at the interface of composites [72].

Cost of fabrication of AMCs with nano sized reinforcementis generally very high. This is due to the higher cost of obtainingnano sized reinforcement. Though various synthesis and pro-duction techniques of nano reinforcement (particles and fibers)have been developed but there is a need to develop the methodsto produce nano sized reinforcement in large quantity and whichhave affordable cost. There exist a need to develop processingtechniques for nano and hybrid AMCs which gives uniform dis-tribution reinforcements, preserve the nanostructure in endproduct without excessive grain growth and able to produce itin bulk quantity to reduce the cost. The process control and opti-mization of process parameters plays an important role in reduc-ing the cost of production of nano and hybrid AMCs.

7. Conclusion

Most of Al based nano and hybrid composites developedare at research stage only. These composites have great futuredue to their superior performance. These composites are antic-ipated to have substantial applications in automobiles, aero-space, marines, sporting goods, etc. Nano sizedreinforcement is key element in the development of nanocom-posites. Synthesis and production of nano powders at afford-able cost will make the use of nanocomposite popular infuture. The challenging aspect of nano and hybrid compositemanufacturing is the ability to create nanostructure materialshaving novel properties at macroscale because manufacturingtechniques strongly affect the morphology and materials prop-erties at nano meter level. Agglomeration and clustering ofnano sized reinforcement is prominent in manufacturing nanocomposites which affect the uniform distribution of it in matrixmaterial. Ultrasonic probe assisted cavitation method is one ofthe promising method to address this problem and successfullyused by the researchers to manufacture bulk nanocomposite.The conventional processing methods have strong limitationto preserve nanostructure in the final product due grain growth.So development of suitable consolidation and densificationtechniques for nano and hybrid composites is need of an hour.Handling of nano reinforcement is a challenging task as ultra-fine nano particles have high surface area and are susceptible tocontamination due to their high surface activity which in turndegrades physical, chemical and mechanical properties ofAMCs. To harness nano size effect to the fullest extent han-dling of nano reinforcement with utmost care is required.

This work has attempted to present one overview and focuson importance of Al based metal matrix nano and hybridcomposites.

10 A.V. Muley et al.: Manufacturing Rev. 2015, 2, 15

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Cite this article as: Muley AV, Aravindan S & Singh IP: Nano and hybrid aluminum based metal matrix composites: an overview.Manufacturing Rev. 2015, 2, 15.

A.V. Muley et al.: Manufacturing Rev. 2015, 2, 15 13