Properties, Production Process, and Applications of Aluminium Metal Matrix Composite Foams

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Abstract
A metal matrix composite refers to a composite that has two or more reinforced materials that
have been added to it so as to enhance the properties of the composite. A metal matrix receives
more favour than polymer matrices owing to their ability to satisfy the engineering demands.
Aluminium metal matrix composites include such composites as which aluminium has been used
as the matrix and include numerous reinforced materials that are embedded into the matrix.
Owing to their qualitative properties such as high thermal conductivity, low density, excellent
mechanical properties, high damping capacity, high specific strength, high resistance to
temperature, low thermal expansion coefficient, high ratio of strength to weight, corrosion
resistance and high resistance to wear as well as high abrasion, they have remained to be on high
demand. The various properties and applications of aluminium metal matrix composite foams
and the production processes including direct injection of gas injection of gas and foaming
precursors are studied. Recommendations are made that the two production procedures to be the
most ideal in the production of composite metals and consideration to be given to the properties
before they are applied for various use.

Contents
Abstract.......................................................................................................................................................2
CHAPTER ONE: INTRODUCTION...................................................................................................................4
Background of the Study.........................................................................................................................4
Aims and objectives.................................................................................................................................5
Research Gap and Research Questions...................................................................................................5
Innovation and Significance, Expected Outcomes...................................................................................6
Resource requirements...........................................................................................................................7
CHAPTER 2: LITERATURE REVIEW................................................................................................................8
Properties of Metal Foam........................................................................................................................8
Structural properties...............................................................................................................................9
Mechanical Properties of Metal Foams Matrices of Aluminium Composites........................................10
Elastic Response................................................................................................................................10
Mechanical properties...........................................................................................................................13
Production Process................................................................................................................................18
Production of Aluminium Composite Foams through direct forming by gas injection......................20
Foaming of precursors.......................................................................................................................21
Applications of aluminium Alloy Composites........................................................................................22
Structural Applications......................................................................................................................22
Functional Applications.....................................................................................................................25
CHAPTER THREE: RESEARCH METHODOLOGY...........................................................................................28
Preliminary Development of the project...............................................................................................29
Timeline.................................................................................................................................................29
CHAPTER FOUR: DATA ANALYSIS...............................................................................................................30
Classification of metals based on their properties.................................................................................30
Applications of composite metals based on their properties................................................................32
CHAPTER FIVE: CONCLUSION AND RECOMMENDATIONS.........................................................................35
References.................................................................................................................................................37

CHAPTER ONE: INTRODUCTION
Background of the Study
A metal matrix composite refers to a composite that has two or more reinforced materials that
have been added to it so as to enhance the properties of the composite. A hybrid metal matrix
composite on the other hand has three or more composites that have been brought together with
the matrix. Other than the common metal matrix composite, there exits polymer matrix
composite, PMC, as well as ceramic matrix composite, CMC. Generally, a metal matrix receives
more favour than polymer matrices owing to their ability to satisfy the engineering demands.
Composites have become the top most promising materials in the recent past with modern
science applying the concept of mixing two or more various materials to come up with better
quality materials Rohatgi et al., 2006. Such combinations results into unique properties which are
in most cases advantageous. There is starting recognition and acknowledge of the commercial
uses of composites by the composite industry and thus increases the chances of greater business
opportunities in both the automotive and aeroscope sectors. Aluminium, titanium and
magnesium alongside their alloys are the frequently used metal matrix.
Aluminium metal matrix composites include such composites as which aluminium has been used
as the matrix and include numerous reinforced materials that are embedded into the matrix.
Among the most commonly used reinforced materials for aluminium metal matrix composites
include red mug, silicon carbide, ly ash, cow dung, graphite and rice husk among other
reinforced materials.
Owing to their qualitative properties such as high thermal conductivity, low density, excellent
mechanical properties, high damping capacity, high specific strength, high resistance to
temperature, low thermal expansion coefficient, high ratio of strength to weight, corrosion

resistance and high resistance to wear as well as high abrasion, they have remained to be on high
demand. This matrix offers lesser wear resistance in comparison to steel and thus widely applied
as a matrix metal. Numerous and wide range of techniques can be used in the manufacture of
aluminium metal matrix composites including squeeze casting, stir casting, powder metallurgy,
and chemical vapour decomposition among other production methods. Of the manufacturing
techniques, stir casting has remained to be the most common method that is adopted by analysts
and researchers.
Aims and objectives
Aim of this research is to explore production process, properties, and applications of metal foams
matrices of Aluminium Composite so that researcher can understand what reinforcements or
metal foams can be used to make aluminium composite suitable for specific applications. To
achieve this aim of the research project, following objectives would be fulfilled:
 To understand properties of metal foams matrices of Aluminium Composites
 To understand various methods of AMC metal foams production
 To explore various applications of Foamed AMCs
 To understand what types of metal foams add properties to make the metal suitable for
specific applications
Research Gap and Research Questions
Aluminium metal matrix composites among other metal composites have been in the market for
decades and their applications have cut across all the sectors both in the industry and domestic
sectors. Following their qualitative properties such as high thermal conductivity, low density,
excellent mechanical properties, high damping capacity, high specific strength, high resistance to
temperature, low thermal expansion coefficient, high ratio of strength to weight, corrosion

resistance and high resistance to wear as well as high abrasion, they have remained to be on high
demand. This matrix offers lesser wear resistance in comparison to steel and thus widely applied
as a matrix metal. Numerous and wide range of techniques can be used in the manufacture of
aluminium metal matrix composites including squeeze casting, stir casting, powder metallurgy,
and chemical vapour decomposition among other production methods. Despite the numerous and
varieties of applications of matrix composite foams, not so much has been explored when it
comes to various properties of these foams and how these properties influence their applications.
An understanding of this scenario would be exploring the various composite metals and using the
various properties as the basis of classification. This would begin at the point of classification of
the various known metals using their identifiable properties.
Among the research questions include:
 What are the properties on which metals are classified?
 What are the properties of various composite metals?
 What are the various applications of composite metals?
 Which production methods are recommended for composite materials?
Innovation and Significance, Expected Outcomes
A comprehensive study into the various metals, their properties and the composite metals would
offer insights into how best appropriately the composite metals can be applied based on the
studied properties. It is thus expected that by the end of this study, there will be a clear cut and
elaborate guidelines that can be followed in the utilization of composite materials for various
purposes. In so doing, better quality equipment and products will be attained as focus will be
directed on the best mix as dictated by the prevailing circumstances.

Resource requirements
For this work, the researcher would not need any financial or human resources other than the
researcher. For the research, the researcher would need to explore the journal articles and
research reports from the library. For this, the researcher would use the college library and the
online sources like Google Scholar and other online research databases to collect required data.
As the data can be collected by a single individual if sufficient time is provided, the research
would not need any other human resource for the current research except the research who would
be visiting the library and online sources to get access to the reports and related data.

CHAPTER 2: LITERATURE REVIEW
For numerous years now, there have been tremendous attempts among scientists and engineers in
coming up with porous metals and metal foams in a bid to copy the naturally porous materials
including bones, cork and coral. Metal foam is a cellular structure that is composed of a solid
metal having a large volume fraction of pores that are filled with gas. The pores may be sealed or
be in an interconnected network. When the pores are sealed, the foam is referred to as closed-cell
foam while the foams are called open-cell foams when in an interconnected network. The closed-
cell foam is commonly known as the metal forms while the open-cell form is called a porous
material. Aluminium is the most commonly used in the manufacture of metal foeman even
though there are other numeracy metals that are applicable among the tantalum and titanium
Jiejun et al., 2003.
Properties of Metal Foam
The properties of the foam of aluminium metal matrix composites are members of a group of
materials known as cellular solids which are often defined to be having a porosity of up to
greater than 0.7. Plants and animals are the main producers of natural foams include bone and
coke while arrival foams many be produced from various materials among the metals, polymers
and ceramic. The two main categories of manmade foams include closed-cells and open-cells.
Metal form is able to combine the properties of cellular materials with the metals from which
they are a component. This makes metal foams be beneficial when it comes to lightweight
construction following the high strength to weight ration besides the functional and structural
properties such as sound management, heat management and energy absorption. It is possible to
foam numerous metals and their corresponding alloys.