Metal matrix composite materials

L. D. BLACKBURN, F. R. BONANNO, H. M. BURTE,

J. A. HERZOG and VV. F. STUHRKE

OMPOSITF materials, especially metal matrix com- composite, and prediction of composite properties from
C posite materials are possible substitutes for metals
in use today. However, because they can possess
extremely high strengths, moduli and excellent high
the properties of the components and the geometry of
the microstructure. Comprehensive reviews of the
literature on filament-metal matrix composites have
temperature properties they may be employed most recently appeared."
profitably in applications which do not presently exist, The simple concepts of reinforcement in unidirectional
since no present material has the required capabilities. composites have been fairly well established, Thus,
In addition, their present high cost and very early stage the work of McDanels, Jech, and Weeton3 in Fig. I
of development make them unlikely candidates for mate- shows that the modulus of a copper matrix-continuous
rials substitution in the context of this meeting. This tungsten wire composite can he predicted by a linear rule
paper is oriented more towards the development of of mixtures.
composite materials for aerospace structures.
Ultimately composite materials, especially metal E , = E,V,1 E,,,( l-V,)
matrix composites may become vital materials in the
industrial growth of a nation. The employment of Where E is modulus, V is volume fraction of a compo-
composite technology may permit the large scale substitu- nent, and the subscripts c, f, and m refer to composite,
tion of aluminium for the more scarce metal copper in filament and matrix, respectively. In a composite con-
high voltage electrical transmission. The improved taining discontinuous filaments, shear within the matrix is
strength and strength retention at temperature of axially necessary to transfer the load to and between the fila-
reinforced aluminium composites would permit significant ments. The work of Sutton and Chortle," for example,
increases in the power carrying capability of the alu- shown in Fig. 2 for the model system of AI,O, whiskers
minum due to the high permissible operating tempera- in silver demonstrates that reinforcement can occur.
tures. In addition, other significant savings would be The shear strength of the matrix and of the bond
found in the ability of the composite to support its weight developed between the filament and the matrix in these
over longer distances due to higher tensile strength and specimens is sufficient to permit most of the strength
improved creep resistance. This could reduce the number of the filaments to be developed in the composite. Again,
of support structures by more than a factor of two. a simple linear rule of mixtures provides a relatively
This brief example is only one of the potential ways in good fit of these data. Some preliminary work from our
which these new metal matrix composite materials can own laboratory, such as on the boron filament-metal
ultimately provide a better life for us all. matrix composites shown in Fig. 3 also demonstrates
Glass filament-polymeric matrix composites already that significant reinforcement can occur. For 7.5 volume
have become familiar materials in uses ranging from per cent filament the strength and modulus of this speci-
light-weight luggage to high performance solid propel- men were increased by 17 per cent and 27 per cent respec-
lant rocket motor cases. D uring the last decade there tively over that of the unreinforced matrix.
have been a few developments-oriented attempts to in- Interest in metal matrix composites received its most
corporate glass or metal wire filaments in metal matrices, significant stimulus from the emergence of a variety of
but these did not generate any significant practical new, high modulus, high strength, low density and often
enthusiasm. Some work with such filament-matrix refractory filamentary materials. Table I shows the
combinations, particularly during the last few years, properties of a few of these and of some typical glass and
has been very valuable from the viewpoint of model metal filaments. To a first approximation, the distribution
system information to stimulate and verify theoretical of stress between the components of a composite will be
micromechanics. The latter involves analysis of stress in proportion to their moduli of elasticity. Thus, since
and strain distribution between components of the the moduli of some of these filaments are significantly
greater than those of potential metal matrices such as
Lt. L. 1). Blackurn, Major F. R. Bonanno, Mr H. M. Burte,
Mr J. A. Herzog and Lt. W. F. Stuhrke, AF Materials Labo- aluminum, titanium, or even steel and nickel, they can
ratory, Wright .Patterson AFB, Ohio, USA. act as efficient reinforcements, Since, in addition, their

43
Blackburn et. al.: Metal matrix composite inalerlals

3 Macrostructure of alcunituuin-boron composite )chich

exhibits fiber reinforcement x 25
0 20 4U 6o &U 100

I
1 Dvnarnic modules of elasticity of tungsten, copper, and densities are low, improved strength to weight ratios are
copper reinforced with tungsten wires (McDANELS ET
AL (4) )
potentially attainable in metal matrix composites with
these filaments. The availability of it variety of these as
continuous filaments, and the promise of more such as
high modulus, high strength carbon filaments, has led to a
major acceleration of activity and interest in metal matrix
composites.

TABLE I Filament properties

Tensile Elastic Density, Strength/

Material strength, modulus, lbs. in.J Density,
psi psi in.

400

Beryllium 180 45 > 106 (1066 2'73 x 108

Molybdenum 320 48 „ 0.369 0.88 „
Steel 600 29 „ 0-283 2.12
Tungsten 580 59 „ 06,97 0'83
F-Glass 350 l0 .. 4092 3.81
Silica 500 l0 (1079 6.35
Boron 400 55 „ 0083 4'82
200
Carbon 200 25 0060 2'17
Silicon carbide 400 70 „ 0.142 2.79
Alumina whiskers 2000 75 „ 0.143 24.50
Graphite whiskers 350 45 „ 0 060 5 84
Silicon carbide
W
whiskers 1500 123 .. 0-115 1300
in 7irconia whiskers 126 26 ., 0.200 0.63
0

0 IC ?p 5.0 40
0

VOLUME PERCENT WHISKERS ( uAI2031

The current activity in this field in our own laboratory
and in the United States in general can be divided into
2 Tensile strength of silver-alumina whisker composites ( Sutton
and Chorne (7) ) the following major categories

44
 BIarkburer et. a!. r Metal m a trix eontposile materials

( a) Development and characterization of filaments. Al 20.1 WHISKERS ( FRCM REFERENCE 22)

(b) Analysis of the micromechanics of composites s CLASS )

i.e., of the detailed nature of the stress and strain E OIASS ,
(FROM REFERENCE 2I)

distribution among the components of a composite

as a function of external loading. bUKUN )
! (FMOM REFkRENCL 24)
SiC

(c) Study of filament-matrix interactions, including

M. WINS ( FROM NEFERENCE 25)
the nature of the interfaces and the reactivity or
stability of the components (chemical reaction,
dissolution, etc.) towards each other during both
composite preparation and use.

(d) Preparation of and characterization of the

behaviour of a wide variety of filament-matrix
composites.

(e) Comparison of composite properties with the

requirements of potential uses.

(f) Development of test and analysis methods by

which suitable materials properties may be cor- Tt MPI HAILRF •F

related with and used to predict component 4 / filament sire m t!r as a fjuuetion of temperature
performance.

Analysis of possible future uses for metal matrix comb structure of titanium when this would be more
composites will depend upon properties and behaviour efficient.
which are attainable. These. in turn, can be varied very Two points of view will now be delined for a discussion
extensively as a result of the highly anisotropic contri- of future potential. One extreme considers metal bonded
bution of the filaments to overall properties and the filaments. the other considers reinforced metals. Actual
opportunity to control the geometry of filament location future development will. of course, involve considerations
with respect to the external loading imposed on it between these extremes, but knowledge of the behaviour
structural component. of metal matrix composites is not yet sufficient to warrant
We shall outline first the possible directions of develop- a much more refined analysis. Consider first the metal
nient interest for metal matrix composites followed by an bonded filament approach which focuses attention on
analysis of the status of theory for, and experimental the extreme strength or modulus to density ratios availa-
verification of their inicromechanics. We shall then ble in filaments, and attempts to devise ways of efficiently
discuss and illustrate several topics of current experi- using these in lightweight structures. This might be
mental interest and present techniques and results in the considered a direct outgrowth of existing polymer
characterization of some of the new filaments and the bonded glass filament composite technology. The poten-
interactions Which occur in metal matrices. tial for metal bonded filaments is best evaluated by
considering the reasons, it' any, for a metal matrix rather
Potential for metal matrix composites than a polymer.
The most obvious potential advantage of a metal
Analysis of the potential for future development and use matrix is in resistance to long time exposure to many
of any new materials must be done within a framework severe environments. Temperature will he used to illu-
of competition both with other possible materials and strate ; advantages in resistance to chemical attack and
materials development routes, as well as with the variety erosion, either singly or in combination s\ith eleva-
of different ways in which a designer may use materials ted temperature, are also probable. Fig. 4 shows the
to perform it function. Initially, the properties of nmate- strength of some currently available filaments as a
rials are compared. Eventually, of course, the cost- function of temperature. Very attractive strength re-
effectiveness of competing combinations of materials, tention suggests combination with appropriate matrices
fabrication processes and designs should (lictate actual to provide high temperature composites. Specific com-
selection and use. parisons will depend on the nature of the application,
To correctly assess future potential, comparison the loading, the time at temperature and other factors,
should be with appropriate existing and possible future but it is reasonable to assume that metal matrices may
competition. Thus, it metal matrix composite for use at provide significant competition to polymer matrices at
600"F should be compared to titanium alloys, not temperatures above about 250` F. Other possible
aluminium, even if the matrix is aluminium. Further, the advantages of metal matrices can be derived by con-
comparison should consider not only the materials them- sidering some of the factors which currently prevent
selves but also the most efficient ways of using materials ; using the unidirectional strength to weight ratio of
i.e., not only a sheet-stringer structure, but also a honey- filaments as a direct indication of the weight of the

45
 Blackburn et. al . : Metal matrix composite materials

TABLE ' 11 Weight comparison of rocket motor cases (12) extreme would offer very real advantages. Existing
technology for the reliable and effective design, fabrica-
tion and use of metals would be applicable. and new
Strength , Density, Strength Case
Material psi lb./in' Density, weight, materials could find early acceptance and use. However,
in. lb. such an uncomplicated possibility is unlikely, and
attention must he directed towards determining the
nature and extent of differences between fiber reinforced
Steel Alloy 200x 103 0283 0.71 x 10, 536 and conventionally strengthened metals.
Titanium Alloy 160 „ 0-160 1 -04) „ 321 Finally, some comments relative to the use of various
E. Glass Filament 350 „ 0.092 3.81 „ 301 classes of filaments with metal matrices are appropriate.
S 994-Glass Filament 437 „ 0088 4-97 254 If appropriate strength or modulus to density ratios of
the filaments alone are compared, metal wires are not
attractive relative to glass, boron, silicon carbide, etc.
filaments. High strength beryllium wires would be a
structural elements made from them and polymer singular exception. Thus, there is as yet little basis for
matrices. Table lI is derived from a recent study' the use of metal wires in the metal bonded filament
into the optimization of polymer matrix-glass filament approach. For reinforced metals, the ahilit', of a metal
wound solid propellant rocket motor cases. For a wire to show plastic yielding, as contrasted to the essen-
specific application the weight of optimized filament tially elastic behaviour of most other filaments, might
wound cases is compared to that for cases fabricated be of some value in permitting deformation processing
from metals with the design allowables shown. Note of the composite without unacceptable breakdown of
that the enormous increase in strength-to-density ratio the filaments, or in contributing to fatigue and impact
between the "homogeneous" metals and the filaments resistance. Glass filaments do not have higher moduli
is not reflected in a comparable decrease in the than potential matrix metals such as aluminium or tita-
weights of final cases. Some of the reasons for this nium. Ho\Never, if the metal tnatri\ is allowed to yield
are as follows : plastically, its effective modulus to use in determining the
microstress distribution within the composite will by the
(a) The composite is, of course, not 100% filament. tangent modulus and significant reinforcement by glass
These particular examples contained 18'8% weight filaments can be demonstrated. The glass filaments may
% epoxy. Although the polymer matrix performs also influence crack propagation resistance.' Whether
a necessary function in permitting the strength of this implies advantages for glass. relative to the use of
the filaments to be utilized, it is generally assumed higher modulus filaments, is not yet clear.
that it does not itself provide a significant addition High modulus filaments are currently of prime interest
to either the strength or elastic modulus of the for use in reinforcing metals. Continuous filaments
composite. such as boron or silicon carbide will he applicable to
(b) The filaments are assumed to be effective only either of the development approaches discussed above.
along their axes. If the application involves a Short filaments such as whiskers will initially he of in-
multiaxial stress field, additional filaments must terest primarily in a reinforcement approach. Higher
be added to bear the load. volume percentages of such discontinuous filaments
c) Additional reinforcement must be added to the might also eventually he approached in a variety of ways
filament wound structures to cope with stiffness such as forming :t whisker-metal matrix wire for use
requirements and for cutouts, attachments, stress in filament winding.
concentrations, i.e. at any point where stresses
transverse to the filaments or shear loads occur Microinechanics of metal matrix composites
or where the continuity of the filaments is dis-
turbed or both. Most of the past theoretical and experimental analysis
of the mechanical behaviour of composites has been
In addition, a metal can offer very significantly greater developed within the framework of polymer matrices.
tensile, shear and hearing strength as well as greater Some of these results are sufficiently general to apply to
deformation prior to fracture than current polymer metal matrices in the low range of stress where both
matrices. It can itself provide meaningful contribution filament and matrix remain elastic. Beyond this range of
to the elastic modulus of the composite in all directions. stress it fundamental difference appears between metals
Also, if the mechanism by which the composite fractures and polymers. As the load increases, the elastic limit of
involves a statistical accumulation of individual fiber the metal will he exceeded at local areas of' high stress
breaks, a metal matrix may delay the onset of final concentration and plastic flow will occur, accommodating
catastrophic failure and thus increase the strength. the stress distribution at these locations. Further aspects
The reinforced metal approach focusses attention on of metal composite behaviour %vere aptly indicated by
the metallic matrix and the possibility of usefully im- McDanels, Jech, and Wecton'` in their delineation
proving its strength by the addition of' filaments. In the of the stages of deformation as: (a1 elastic deformation
extreme the addition of filaments might be considered of both filament and matrix, b elastic deformation
to be comparable to any other strengthening mechanism of filament and plastic deformation of matrix, (c) plastic
such as cold 'working or precipitation hardening. This deformation of both filament and matrix, and (d) fracture.

46
 Blackburn er. al.: Aleta! n+atrix composite materials

When one considers structural applications, there are a

variety of properties which must he known before any
designer will attempt to use any material. Tsai." has of of fibers
300
shown that in order to characterize the mechanical be-
haviour of a composite material one must know the
longitudinal strength, modulus and Poisson's ratio, the
transverse strength. modulus and Poisson's ratio, and
the shear strength and modulus. Relationships between
the elastic constants of the composite and those of the
individual constituents have been developed by several
workers.-" In general. the ability to predict longitu- ^'. tacit.

dinal strength and modulus under uniaxial tensile loads IUu

is fairly well advanced. Further work is needed to develop

the ability to predict more accurately the transverse and
shear strengths and moduli, and Poisson's ratio. All of
these will include studies of the effects of such micro-
mechanical variables as filament size, packing density, 1.0 20
C r i t i c a l Tr_9n f ennui
interfacial bond strength, and the materials properties Int.rflb . r pacing
of both constituents.
An exact analysis of the micromechanics of a com- 5 EIteci of critical transfer length and interfiber spacing on
J;actnre and ttipe of Jractare in steel wire-lead solder compo-
posite containing discontinuous filaments such as whis- sites (Parikh 17)
kers or chopped fibres does not exist. !Much of what
is known has been summarized in recent reviews.'-',' In-
dications are that the flow of stress or transfer of load
in such a composite is along shear paths from the cir- A ductile or fiber "pull-out" type of fracture is
cumferential surface of one Iilamment through the matrix characterized by failure in the matrix progressing along
to another filament. It is obvious that this mechanism the composite. Brittle fracture is characterized by gross
is strongly influenced by the fibre-matrix interface. continuity in the filament and then proceeding across
The status of knowledge relating to creep and fatigue failure of the filaments, and hence the composite, in
has been succintly indicated by Kelly and Davies' : tension. Ductile fracture is accompanied by a high
"As yet there are no satisfactory analytical treatments value of the work of fracture, and thus toughness ;
which allow prediction of the creep and fatigue behaviour while the brittle fracture involves low fracture energy.
of fibre reinforced composites." This applies equally Here one observes again preliminary indications of the
well to other structural design limiting parameters such important role of the filament-matrix interface, since
as stress rupture, fracture toughness, ductility and yield one way of controlling the critical transfer length and
strength. Some probing experimental efforts, notably thus the type of fracture is by controlling the nature
those of Forsyth et al,'" Baker and Cratchley," and of the interface.
Parikh,17,1" have been initiated in some of these areas.
The effort of Forsyth and co-workers is aimed at Filament characterization
improving creep, fatigue and crack propagation behaviour
of aluminium rather than strengthening the metal. Some of the methods we have developed for examin-
Results to date have shown that incorporation of stain- ing the filaments and measuring their mechanical pro-
less steel wires in aluminium sheets led to improved perties will now be described. Observation of the fiber
creep resistance and fatigue life. under the light microscope should be directed not
The role of the interface in the mechanical behaviour of only at the nature of the surfaces, Figure 6, but also
composites has yet to be treated satisfactorily but it has to search for any fractures or fissures. Figure 7. Me-
not been overlooked. Baker and Cratchley" in some tallographic studies of cross sections and of sections
early observations of silica reinforced aluminium under parallel to the filament provide additional information.
fatigue loading have indicated differences in behaviour Our observations on boron filaments, grown by vapour
between composites having weak and strong boundaries. deposition of boron on a tungsten wire substrate, may
Specimens which had strong interfaces showed better be selected as typical illustration of this procedure
tensile behaviour than those with weak interfaces. The and of' features for which to look.
inverse was true for fatigue specimens, i.e. the weak Optical surface observation of the as-received fila-
interfaces gave better behaviour. ment reveals both a "corn cob" structure, Figure 6
Recently Parikh'7 has been investigating the influence (al, and often contamination of the surface by oil films,
of critical transfer length, fiber diameter and interfiber grease and other substances, Figure 8. Further exa-
spacing on the strength, deformation and fracture mination of the boron filament often reveals extended
characteristics of metal wire-metal matrix composites. straight dark lines on the surface, Figure 9. When
As shown in Figure 5, his preliminary results reveal such a filament is cross sectioned, these can be iden-
that the ratio of the critical transfer length, as me- tified as radially oriented cracks or fissures, Figure
asured by pull-out tests, to the interfiber spacing affects 7. Longitudinally sectioned specimens show the faces
both the tensile strength and the type of farcture. or walls of these fissures ; since they do not exhibit

47
 Blnekhurn et_ cif. : Alf-t( / trrarrix c )mpo+ire nrurerio/s

(u) Borotz Jilanu'ut (e) Boron Jilatnctzr coarinc - f Tr;,',

(Afauu /ircturer A) f 0110 X 1000

(h) Rorun Jiltrnneut (AlunuJuetm-er B) x 1 000 If) Si/icon rrul» r%o Jilauuvri x 101)o

(e) Con enrional gla filament niih ^urfare

(c) Boron filarneni coating --SiC Prortr,rting oil film x I H10
x1000

(h) (. intentional class J . Ianiint cIIarz strlare

(d) Boron filament coating +Ti xi 10)

6. Various filaments with and wick. ut surface coutings

48
 Blackburn el . rd. ' Mcle / mal ix r•or1PosiIt runler icrls

10 Vie ii of longit u dinal forced cru el, in a born filament with

conch oidal fracture lines x 300

any conchoidal fracture lines as commonly seen on

forcefully split filaments , Figure 10 , the fissures pro-
bably occurred during vapour deposition of the
boron.
In some instances these fissures cannot be observed
7 C'rn;s sectioned filament with radial fisrtires 35o by optical scanning since they are overgrown and thus
self-sealed at the surface, Figure 11. If the fissures. are
open to the surface they may acquire contaminants by
condensation of vapours or capillary adsorption of liquids.
This is illustrated by the globules of liquid seen on
the face of the fissure (after the filament was split)
in Figure 12. Such contamination may interfere with
effective filament-matrix bonding.
Since it is the mechanical properties of the filaments
which initially generate interest in their use in com-
posite. these properties should he carefully measured.
The difficult case of a fine, short whisker and the-
mea-surement of its tensile strength and its modulus of
elasticity will be considered. Testing of such a small
specimen requires observation of several essential factors
which are of vital importance for reliable data. These
are : the centricity of load application, i.e., elimination
of moments the exact measurement of elongations for

8 curfaee contamination with oil or grease filet; on boron

filata nt x 1500

9 Longitudinal fissure on the surface 11 View of the face of a fissure in a boron fdcunent X 800

49
Blackh,nrt et. al.: Meta/ n,atri.r composite maleriais

(n) Exploded riesr

12 View of the face of 'a fissure in the boron filament-one side

self- sealed at the surface

the determination of elastic behaviour , the measurement

of the cross sectional area. Equally important is the
accuracy of measurement of' load on the specimen dur-
ing the test . For the sake of convenience , with fine
short fibers or whiskers elongation is often measured
as separation between the grips. However , this con-
venient approach often results in considerable error due
to deformation which can occur in the cement in the grips.
Therefore . it is often desirable to use some type of gage
on the filament itself, and we have been cementing gage (b) Asvemhlerl rieu ' suit/t mire leaps and whisker
marks on the fiber specimen using microntanipulators,
14 1lo „ntiug block for whisker %pecin)ens
Figure 13. The gage marks are actually other whiskers
and are cemented perpendicular to the fiber to be tested
at a specific distance from each other . This distance is
specimen on a microscope. Wire loops are aligned
measured immediately before the tensile test of the
between pins, one fixed and the other removab)Ie and
clamped in a mounting block, Figure 14, and then the
whisker specimen is placed on and cemented to the
center of these loops. This approach with prealigned
mounting blocks increases centricity of the small speci-
mens in the tensile machine and eases the problems
of handling and the danger of accidental damage until
the test can he started. The images of the art- projected on
a screen with the aid of an optical s}stem consisting
of a light bulb with a condenser lens and a high
precision projection lens, Figure 15. These screens are

-1
l,RUlJ%U GEAn

OF SCREEN
GAGE NIAt , S " .E'. •.

I)M.P
CuhDf NSOR ,`^ A IRE tUOP

_LPt1ti MAIt o wi•,

DOLEtu ' r.6 ixF

MV ("ArItk tJ- UI'u

IU1 A: 'I AGNIt ICAI[ON

1 :00300

13 Gage marks on whisker cemented to a wire loop x 15 15 Schematic diagram of the tensile tester

5U
 Blackburn et. el.: .Metal nrafrt.s composite inaterlals

PLEXIGLAS CUBE

TAP OR CEMENL

WHISKER

OIL IMMERSION FRACTURED

( CEDAR 0I1.1 l I ti CROSS SECI IUN

MICROS CCJPE____
0BJECIIVE

16 Arrangement of the fracttoed whisker far tneasuremnent of the

area under the microscope ( Schematic)

2001

F Ii AC T UPI
18 One half of a split and curled boron filament XI
IeoL

I(0L

actually two inch square pieces of ground glass mounted

140E on dial gages of I : 1000 at a distance of 200 inches
from the lens. This provides an amplification factor
of I : 200000'".
120 F After specimen fracture the wire loops with the
fractured part of the specimen still attached are mounted
on one side of a plexiglass block with scotch tape in
I00L such a manner that the specimen tip is protruding a
few thousandths of an inch above the perpendicular
face of' the block, Figure 16. Then the specimen can
N
Ia eo be viewed from the side perpendicular to its axis.2°
Similarly by reorienting the block on the microscope
stage with the specimen axis parallel to the microscope
$0E axis, the fracture area can he seen. The area can he
measured with a micrometer eye piece which should be
precisely calibrated for the exact optical magnification
404 factor. After the strain readings are plotted and the
area is determined, the strength and the elasticity modu-
lus can be calculated, Figure 17.
During handling it was observed that the boron
filaments sometimes split when they are being cut to
desired lengths. This indicates the presence of high
1000 2000 3000 4000 5000 X 10-'
residual stresses. In one instance, a foot long specimen
of a boron filament split during cutting and the two
STRAIN IN/IN
halves curled up in nearly perfect cirices, Figure 18.
Once the splitting started. it progressed slowly but
17 .Stress-strain curve of iron whisker as obtained on the w hisker
tensile tester ( Cross section at fracture = 3'3µt used to continuously until both parts were completely sepa-
calculate stress) rated.

51
Blackburn ri. al.: )tfrial maircx ccnnpo.cite nrc,ierials

20 (1/,., sf, ,,o,, of ;n'iallu ,.r,irvcl bans/ in a Ti-6.41-4V-Boron

ojogw,iii' (CourFe)y NA.-i i.-ID) x 100

(a) Boron Jihers emherh(ed in cr nic1: r'1 ruairi r X25()

Filament -ma(rix; interactions

Two types of bond at the fiber matrix interface should

he distinguished : mechanical and metallurgical. A
mechanical bond is illustrated in Figure 19 by a nickel-
boron composite fabricated h` a molecular forming
process by the General Technologies Corporation.
Figure 19 (a) is a transverse section of the composite
showing the filaments in a nickel matrix. Figure 19 (b)
shows the characteristic ''corn cob' stucture of the surface
of a boron filament. Figure 19 (c) is a longitudinal
section of the composite showing the surface of the
nickel matrix from which a filament hid been extracted
leaving a replica of its surface. ,A metallurgical bond
illustrated in Figure 20 by a Ti-6A 1-4V boron filament

(b) Surface of boron filament

(e) S'cnjuce of' nickel matrix +howhitz replication of horun

Iur/m x x:10

19 1/hrstration of invehanical bond in a nickel-boron composite

(Courtesy General Technologies Corporation) 21 Al-B Contposire (Courtesy NAA L.' D) X 500

52
 Blackburn et. al.: Metal matrix compo site materials

22 Ti-8 .41-fl - iMo-B composite after exposure at 1650 F for 69 24 Fe-B Composite after exposure at 1650 ' F for 1 hour
hours

composite fabricated by the North American Avia- treatment, Figure 23. A sunburst-like diffusion pattern
tionlLos Angeles Division. The compound titanium is illustrated by the iron-boron filament interaction.
diboride forms at the interface between the boron fila- Figure 24. An 18% Ni maraging steel-boron interaction
ment and the alloy. is illustrated in Figure 25. It is entirely different than
The follo%,ing series of examples taken from work that of iron and thus qualitatively shows the effect
done at the AFML will illustrate briefly the types of of matrix alloying elements on the interaction behaviour.
reaction which may result between boron and various Eutectic formation and the resultant cast structure is
metal matrices. illustrated in Figure 26 for a copper-boron com-
In an aluminium-boron composite fabricated by dif- posite.
fusion bonding there is no reaction evident at the Another type of interaction which may occur with
interface, Figure 21. Simple compound formation was composites containing boron filaments is the formation
illustrated in Figure 20 while the growth of this phase of a glass, as illustrated by an aluminium-boron com-
after heat treatment is shown in Figure 22. Complex posite, Figure 27, which was fabricated by powder
compound formation consisting of several phases is metallurgy techniques.
illustrated by a nickel-boron composite after heat The illustrations certainly indicate that a variety of

25 Maraging steel (Fe-18Ni)-boron composite after exposure at

23 Ni-B composite after exposure at 1380 ' F for 1 hour )( 500 1650 -F for 1 hour x 500

53
Blat•hhurn t't. W. Metal matrix composite ntale rials

26 Cu-B Composite after synthesis ), 840

x 500 (a) Refieered f rlrt

interactions may occur. Control of the interface will

be vital, but the nature of this control is not yet
established. Some of the more obvious possibilities
are fiber coating, matrix alloying and the development
of compatible fibre-matrix combinations. Regardless
of' the method or methods chosen, control of the
interface is inherent for control of the mechanical
properties.

Concluding remarks

Filament-metal metrix composite materials show signi-

ficant potential for future development and use. However,
much theoretical analysis and experimental verification
of both micro mechanics of' composites and their be-
haviour under a variety of use conditions, and on the
broad subject of filament-matrix interactions must yet
be done to indicate the possible as well as the most (h) Trancioritierl Irt;ht x ?s0
feasible and attractive directions to follow. The acqu-
isition of reliable experimental data, on reproducible
27 .41-B Composite showing Matsu phure
specimens with well characterized structures, warrants
priority attention.
The overall area of composite materials will demand
References
unprecedented cooperation between activities such as
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Discussions

Mr L. J. Balasundaram , (N.M.L.) : Is there any relation- technique, random alignment technique, etc.
ship between the mode of distribution of filaments in Now about dispersion hardening there is a signifi-
the matrix and the strength of the reinforced material, cant difference between these two materials. On dis-
and if so how do you control it ? persion hardening, size factor is somewhat smaller than
How does the filament reinforced materials compare one is interested in dislocation motion where as in
with dispersion hardened materials ? these materials when a filament is 5/1000 of an inch
which is many tens of thousands of an augstrom
Lt W. F. Stuhrke, (Author) : In reply to your first and speaks about stress interaction rather than
question we were very interested in trying many approa- dislocation interactions. We don't feel this results in
ches to control the distribution of these filaments in any strengthening. We feel that there is really no such
the metal matrix because obviously distribution is what relationship. At the moment we stopped with circular
determines the properties of the particular direction, filaments but we would like to try square ones ; hollow
the material being extremely anisotropic. We are trying ones ; as a matter of fact the technology of distribution
a number of different methods ranging from diffusion is not much advanced.