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Project report

btech first year (Netaji Subhas Institute of Technology)

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A STUDY OF METAL MATRIX COMPOSITES (MMCs) IN

ADVANCEMENT OF AUTOMOTIVE PARTS

A PROJECT REPORT
Submitted by
Kanishka Singh (1709740057)
Santosh Kumar (1809740135)
Satyabrat Yadav (1809740137)
Utkarsh Dwivedi (1809740172)

Department of Mechanical Engineering

Galgotias College of Engg. & Tech., Gr. Noida
Dr. APJ Abdul Kalam Technical University, Lucknow

May 2022

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A STUDY OF METAL MATRIX COMPOSITES (MMCs) IN

ADVACEMENT OF AUTOMOTIVE PARTS
Project Report
Submitted to
Dr. APJ Abdul Kalam Technical University, Lucknow

In partial fulfillment of the requirements for the award of The

Degree of Bachelor of Technology In
Mechanical Engineering
by
Kanishka Singh (1709740057)
Santosh Kumar (1809740135)
Satyabrat Yadav (1809740137)
Utkarsh Dwivedi (1809740172)

Under The Supervision of

Dr. Anil Kumar Shrivastava
Professor

Department of Mechanical Engineering

Galgotias College of Engineering & Technology,
Greater Noida
May 2022

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DECLARATION
We, Kanishka Singh, Santosh Kumar, Satyabrat Yadav, Utkarsh Dwivedi, student of B. Tech.
(ME) hereby declares that the project title <A STUDY OF METAL MATRIX
COMPOSITES (MMCs) IN ADVANCEMENT OF AUTOMOTIVE PARTS” which is
submitted by us to the Department of Mechanical Engineering, Galgotias College of
Engineering and Technology, Greater Noida (Affiliated by Dr. A.P.J. Abdul Kalam Technical
University, Lucknow) in partial fulfillment of the requirement for the award of the Degree of
Bachelor of Technology has not previously formed the basis for the award of any degree,
Diploma other similar title or recognition.

Place: Gr. Noida

Date: 22/05/2022

Kanishka Singh (1709740057)

Santosh Kumar (1809740135)
Satyabrat Yadav (1809740137)
Utkarsh Dwivedi (1809740172)

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GALGOTIA COLLEGE OF ENGINEERING &TECHNOLOGY

BONAFIDE CERTIFICATE

Certified that this project report <A STUDY OF METAL MATRIX COMPOSITES

(MMCs) IN ADVANCEMENT OF AUTOMOTIVE PARTS= is the bonafide work of

<Kanishka Singh, Santosh Kumar, Satyabrat Yadav, Utkarsh Dwivedi,= who carried out

the project work under my supervision.

Dr. Mohd Asim Qadri Dr. Anil Kumar Shrivastava

HEAD OF DEPARTMENT SUPERVISOR
Galgotias College of Engineering Galgotias College of Engineering
& Technology, Greater Noida & Technology, Greater Noida

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ACKNOWLEDGEMENT
We would like to thank our college and department in helping us to select our project. We
would like to express my gratitude and appreciation to all those who gave us the possibility to
complete this report. Special thanks to our supervisor Dr. Anil Kumar Shrivastava whose
help, suggestions and encouragement helped us in writing this project report. We are very
thankful to our Head of Department Dr. Mohd Asim Qadri for supporting us. We would also
like to acknowledge the professors of Mechanical department for their valuable supports and
continuous guidance.

Kanishka Singh (1709740057)

Santosh Kumar (1809740135)
Satyabrat Yadav (1809740137)
Utkarsh Dwivedi (1809740172)

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Abstract
The objective of this project is to find out the substitute metal matrix composite materials for
the automotive parts over conventional materials. The metal matrix composite material-based
parts can be used in automotive sector because of its lightweight, high strength and easy to
fabricate. The metal matrix composite material based automotive parts provide better
automotive parts to automotive industry. Mainly squeeze casting, stir casting and powder
methodology are used to fabricate metal matrix composite materials.

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Table of Content

Title Page No.

Deceleration ......................................................................................................................... ii

Certificate ............................................................................................................................ iii

Acknowledgement ............................................................................................................... iv

Abstract ................................................................................................................................ v

Table of content ................................................................................................................... vi

List of figures ..................................................................................................................... viii

CHAPTER-1
1. Introduction....................................................................................................................... 1
1.1. Classification of composite material ............................................................................... 1
1.1.1. Metal matrix composite .............................................................................................. 2
1.1.2. Polymer matrix composite .......................................................................................... 2
1.1.3. Ceramic matrix composite ...........................................................................................2
1.2. Method of fabrication of composite materials ................................................................ 3
1.2.1. Stir casting ................................................................................................................. 3
1.2.2. Infiltration .................................................................................................................. 3
1.2.3. Powder metallurgy ...................................................................................................... 4
1.2.4. Diffusion bonding… ....................................................................................................4
1.3. Uses of metal matrix composite in automobile ................................................................ 5

CHAPTER-2
2. Metal matrix composite .................................................................................................... 6
2.1. Aluminum based metal matrix composite ...................................................................... 6
2.2. Magnesium based metal matrix composite...................................................................... 7
2.3. Copper based metal matrix composite ............................................................................ 8

CHAPTER-3
3. Some method of manufacturing metal matrix composite ................................................... 9
3.1. Squeeze casting… .......................................................................................................... 9
3.1.1. Casting parameters ..................................................................................................... 10
3.1.2. Advantage of squeeze casting process........................................................................ 10

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3.1.3. Disadvantage of squeeze casting process .................................................................. 11

3.2. Stir Casting ................................................................................................................. 11
3.2.1. Advantage of stir casting process .............................................................................. 12
3.2.2. Disadvantage of stir casting process .......................................................................... 13
3.3. Powder metallurgy ....................................................................................................... 14
3.3.1. Powder metallurgy technologies ................................................................................ 15
3.3.2. Advantage of powder metallurgy ............................................................................... 16
3.3.3. Limitation of powder metallurgy ............................................................................... 16
3.3.4. Application of powder metallurgy ............................................................................. 17

CHAPTER-4
4. Application of metal matrix composites .......................................................................... 18
4.1. piston ........................................................................................................................... 18
4.2. Disc brake ................................................................................................................... 19
4.3. Drive shaft ................................................................................................................... 20
4.4. Leaf spring… .............................................................................................................. 21
4.5. Crown and pinion ......................................................................................................... 21

CHAPTER-5
Result ................................................................................................................................. 23

CHAPTER-6
Conclusion ......................................................................................................................... 24

References.......................................................................................................................... 25

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List of figures

Fig-1 Classification of composite material

Fig-2 Methods of fabrication of composite
Fig-3 Process of powder metallurgy
Fig-4 Primary aluminum production
Fig-5 Squeeze casting process
Fig-6 Schematic of stir casting setup
Fig-7 Process of stir casting
Fig-8 Stir casting
Fig-9 Flow chart of powder, metallurgy process
Fig-10 Powder of metallurgy process
Fig-11 Robust macro structure
Fig-12 Fabricated AZ91 and AZ91/3.0 MMC piston
Fig-13 Disc brake
Fig-14 Drive shaft
Fig-15 Imported model
Fig-16 Leaf spring
Fig-17 Crown and pinion

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CHAPTER -1

1. Introduction

Composites are materials consist of minimum of two or more macroscopically

distinguishable constituent materials. Single constituents have distinct physical or chemical
qualities, when combined together give the composite its own set of characteristics. When
two different material having different physical, chemical and mechanical properties fuse
together in order to get single material properties know as composite material. The primary
material can be organic, metal or ceramic.

Reinforcement materials do not fuse into each other and remain separate within the finished
construction, which separates composites from mixes and solid solutions. At least one
material serves as reinforcement and one material serves as matrix in a composite (also
referred to as binder). Composite materials are validly required in many industries for its
versatile properties viz magnificent thermal properties and extraordinary mechanical
properties, high strength viz wear, fracture toughness and corrosion resistance. Composites
have been around since the dawn of time. Mud bricks and concrete were common early
composites. Composites today are frequently more complex.

1.1. Classification of Composite Material

Fig. 1. Shows the classification of composite material.

Classification of composite materials

Based on scale Bio-composite
Based on reinforcement Based on matrix material
Nano-composite
Fiber reinforced Polymer
Particles reinforced Ceramics
Sheet molded Metal

Fig. 1. Classifications of composite material

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Composites are typically classified based on the matrix or reinforcement material, such as
Polymer Matrix Composites (PMCs), Ceramic Matrix Composites (CMCs) and Metal Matrix
Composites (MMCs) (Dipen Kumar Rajak, Durgesgh D. Pagar, Ravinder Kumar, Catalin I.
Pruncu, 2019).

1.1.1. Metal Matrix Composite

Metal matrix composites (MMCs) are a type of material made up of a metal and another
component fused together. These two components emerge in physically and chemically
different stages. The basic material is a metal matrix, with the additional ingredient appearing
as fibers or particles that act as reinforcing material.

The purpose of making such a material, as with other metal matrix composites, is to improve
the metal matrix's current qualities by adding extra features provided by the reinforcement. It
is generally used for enhancing the current properties of materials viz magnificent abrasion
resistance, high temperature operation, excessive strength, excessive heat resistance, thermal
conductivity, high shear strength. Metal matrix composites are expected to develop rapidly,
and their progress will lead to a rise in their number of applications. The automotive industry
consumes a significant portion of global MMC production.

1.1.2. Polymer Matrix Composite

A polymer (resin) matrix is combined with a fibrous reinforcing dispersed phase to form a
polymer matrix composite (PMC). PMCs are made up of thermosetting plastics or
thermoplastics with carbon, glass, Kevlar, and metal fibers dispersed throughout. Because of
their excessive strength and resistance to high temperatures, thermoses are more commonly
used than thermoplastics. Polymer Matrix Composites are extremely in demand because of its
cheap price and simplicity of fabrication. It has versatile characteristics like low cost, high
stiffness, good abrasion resistance, high tensile strength, high fracture toughness and good
puncture resistance.

1.1.3. Ceramic Matrix Composites

Ceramic matrix composites are a type of composite that uses ceramics for both reinforcement
and matrix. The matrix material carries everything together while the reinforcement provides
its unique properties. CMC’s typical properties are low density and high corrosion resistance
at high temperature, high stiffness, toughness and thermal stability. They were created to
counteract the brittleness of monolithic ceramics. CMCs are known as inverse composites

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because the matrix failure strain is lower than the fiber failure strain. It has numerous
applications in various fields like High-performance braking systems, Bulletproof armor,
Heat exchangers, turbo jet engine components etc.

1.2. Methods of Fabrication of Composite Materials

Fig. 2. Shows the different methods of fabrication of composite materials.

Processing Methods

Liquid State In –Situ Fabrication Solid State

Stir Casting Powder Metallurgy

Infiltration Diffusion Bonding

Fig.2. Methods of fabrication of Composite Material

1.2.1. Stir Casting

MMC stir casting was first done in 1968. Powder form reinforcing phases are usually
distributed into molten metals by mechanical stirring in this process. Metal is melted in a
crucible first, then reinforcing particles are added to the vortex created by a mechanical
stirrer. A mechanical stirrer is simply a rotating blade made of materials with a higher
melting point than molten metal. After that, the mixture is poured into prepared mould
leaving for solidification. Sintering and compacting in a hollow die are the final step.

1.2.2. Infiltration

Infiltration is liquid state processing method of fabricating metal matrix composite, in which
performed in which a preformed ceramic particle, fibers, woven in dispersed phase are meant
to be soaked in a molten matrix metal, which further required to fill up the space between the
dispersed phase inclusions. It has several further types viz Gas Pressure Infiltration, Squeeze
Casting Infiltration and Pressure Die Infiltration.

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1.2.3. Powder Metallurgy

MMC may be made using a variety of manufacturing processes. Powder metallurgy is one of
the most extensively utilized fabrication procedures for MMCs that has recently been
developed. In this process, at high speed, mechanical stirring is applied to unfold
reinforcement material and distribute the reinforcement material in powered metal. After the
mechanical stirring, the turbid liquid was dried by ejecting drying technology, during which a
specific temperature is maintained. Dried powder is pressed at a specific pressure and room
temperature to form a compact, which is generally known as a green compact. The green
compact is now ready for Sintering. Fig. 3. Shows process of powder metallurgy.

Fig. 3. Process of powder metallurgy

Compact at a predetermined temperature for a predetermined time period. Afterward, we get

our desired metal matrix composite (H. Yu, S.Q. Zhang, J.H. Xia, Q. Su, B.C. Ma, J.H. Zhou,
X.T. Wang, L.X. Hu, 2021).

1.2.4. Diffusion Bonding

Diffusion bonding is a method that uses atom diffusion in the solid state as a primary step for
the formation of a joint. Diffusion bonding entails maintaining the work components in close
contact under moderate pressure and heating the assembly to a high temperature for a set
period of time. Three steps of bonding occur. Materials yield and creep at the initial step. The
asperities on the joining surfaces deform, and the mating area expands, bringing a
considerable portion of the joining surfaces into contact. Atoms in the contact area diffuse via
grain boundaries during the second stage. The grain boundaries in the bonded zone are

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rearranged, and pores are eliminated. Volume diffusion takes over in the third and final step,
forming the bond.

1.3. Uses of metal matrix composite in automobiles

In most cases, tough materials are chosen for various purposes; lightweight materials have
less strength, while brittle materials have less toughness and fatigue resistance. The hunt for
new and better materials continues, as do current technology needs for more energy-efficient,
durable, lightweight, cost-effective equipment and machines. Composite materials give
numerous features to fulfill these demands.

Metal-matrix composites have a lot of potential for helping automotive engineers satisfy the
needs for recyclable, fuel-efficient, safe, and low-emission vehicles now and in the future.
These materials may be customized to meet the design requirements of automobile
powertrain and chassis components. Although technological and infrastructure limitations
have hampered the use of these materials, it is thought that these obstacles may be overcome
and that metal-matrix composites can be used in high-volume vehicle manufacturing.
Engineers and scientists, managers and planners at vehicle manufacturers, and their suppliers
will have to put in a lot of work to break through these hurdles. As a consequence, metal-
matrix composites will gradually be introduced into high-volume vehicle production to suit
customer demands while also meeting regulatory standards and competitive challenges.
Composites are being examined in the automotive industry to build safer, lighter, and more
fuel-efficient automobiles. The fiber-reinforced composite is made up of a high-strength fiber
(such as carbon or glass) embedded in a matrix material (polymer and metals such as Al, Mg,
and others) that can give enhanced qualities above the separate materials. Composite
materials are used to make several components such as the seat, roof, steering wheel, hatch,
dashboard, carpets, energy absorber, interior and exterior panel, wheels, leaf spring, and
engine cover.

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CHAPTER 2

2. Metal matrix composite

Composite materials are those materials which are contained two, or significantly more,
components with various physical, synthetic and mechanical properties and are synthetically
not the same as one another, yet display a solitary material property. The MMCs got a
noteworthy spot in cutting edge examination and applications from the main improvement to
introduce time and has shown extraordinary possible in the aviation, car, military
applications, electronic instruments and in different ventures.

2.1. Aluminum based metal matrix composite

Aluminum is one of the most famous and normal metal. Aluminum is easy to deal with,
lightweight and having great consumption obstruction, high strength as well as its practical
assembling conceivable through numerous strategies for creation. Aluminium having the high
unambiguous strength however Execution at high temperatures isn't palatable in view of low
liquefying temperature, it has an excellent warm and electrical properties, yet low hardness
and exceptionally low wear obstruction. Aluminum and its compounds most generally
utilized as the grid material in assembling of MMCs.

Fig. 4. Primary aluminum production

Fig. 4. Shows primary aluminium production at global level. The vast majority of the present
metal framework composites are centered around aluminum and combinations for car
applications, generally in motor parts, cylinder, associating poles and Cylinder pins. MMCs
are commonly used to diminish the mass of responding parts in the production of auto motor

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and hence make less commotion and vibrations. The fundamental variable for boundless
utilization of aluminum in auto combinations in examination of other lightweight materials,
like titanium and magnesium, is lightweight and minimal expense. Cylinder works at an
exceptionally high temperature and tension in the chamber so the material which use for both
priority high warm conductivity and high protection from wear. It tends to be utilized for this
which give phenomenal quality at the serious expense and the decrease in the heaviness of a
cylinder can likewise be conceivable. This additionally diminishes the heap on the shaft
which prompts lessen the fuel utilization in the motor and motor power is gotten to the next
level. Car circle brakes and brake calipers are a region where significant weight decrease can
be accomplished. To bring down their expenses and expand machinability for the most part
utilized, artistic built up utilized in slowing down circles of fast trains and in the hustling,
vehicle stopping mechanisms, For the assembling of brake plates and lines Explicit projecting
strategies are utilized. A developing number of vehicles fabricates are presently involving
underway of slowing mechanisms. Aluminium is as yet the great material for railroad
vehicles, Because of lightweight, superb protection from consumption. Marine transportation
has moreover been changed with the utilization of Al combinations and its composites. The
utilization of these materials has permitted an ascent in speed, size, and eco-friendliness of
boats as well as boats. Aluminium based composite materials meet rapid boat development,
assurance and fire peril control details. Aluminum can actually deal with rapid water
transport loads (D.K. Rajak, D.D. Pagar, R.Kumar, C. I. Pruncu, 2019) (M.O. Bodunrin, K.K.
Alaneme, L.H. Chown, 2015) (J. Singh, A. Chauhan, 2016) (K. K. Chawla, N. Chawla, 2014)
(A.L. Craciun, T. Heput, C. Pinca-Bretotean, 2018) (F. Nturanabo, L.M. Masu, G. Govender,
2015) (A.P. Mouritz, E. Gellert, P. Burchill, K. Challis, 2001).

2.2. Magnesium based metal matrix composite

Magnesium is one of the lightest underlying metals have the ability to substitute the
traditional amalgams for mass saving applications and gives higher strength and firmness.
Moreover, it likewise can retain the hydrogen as hydrides and can be utilized as a future
wellspring of energy transporter. The hypothetical hydrogen limit of 7.6 wt. % makes it more
reasonable for future energy sources yet needs to decrease the functioning sorption
temperature. Magnesium combinations are generally utilized in ventures because of low mass
thickness as of late. The higher solidarity to mass proportion makes them as most appealing
materials where diminishing weight is one of the main significances, like electronic edge
creation, sports merchandise, shuttle hardware creation, and ground transport. Magnesium

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amalgams with various added substance materials are very alluring substance for logical
examinations. Tharpe-arranged materials' exhibition relies upon the organization,
manufacture procedure, handling strategies, and properties will be differing with materials
that additional to the magnesium. The metal grid composites (MMCs) made out of low-
thickness magnesium supported with filaments or particles. MMCs offer high strength and
high solidness working at higher temperatures and have brilliant wear-safe properties as the
properties are custom fitted as indicated by required properties (Aghion. E., B. Bronfin., H.
Friedrich., & Z. Rubinovich, 2019) (Anish. R., G. Robert Singh., & M. Siva Pragash, 2020).

2.3. Copper based metal matrix composite

Copper Framework Composites (MMC) have been generally utilized in electrical machines,
vehicles, aviation, bearing and brambles in light of the better mechanical properties, strong
grease and hardness. Presently a day copper and its combination-based composites are
acquiring significance in impending field of designing. Since quite a while, copper-based
metal network composites (MMCs) are acquiring significance underway field. The key
elements which make copper-based metal grid composites significant are Low thickness,
improved weariness strength, high erosion obstruction and higher explicit strength. The
copper metal framework built up with various weight rates of alumina particulates was ready
through the powder metallurgy strategy and various properties of these composites were
assessed. The consequences of porosity show that there is an expansion in Porosity values
with expansion in there is a reduction in the thickness with expansion in Alumina weight rate.
With an expansion in Al2O3 content there is an expansion in the l hardness values. Behavior
of different properties are reinforcement content (You J.H., 2015).

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CHAPTER-3

3. Some methods of manufacturing metal matrix composite

3.1. Squeeze casting

Squeeze casting is a metal-forming technique that involves pressing two dies together. This
method is used to create composite materials comprised of ceramic fibers and molten light
alloy under pressure. Unlike most casting procedures, squeeze casting uses two dies that are
forced together after the metal has been added. The upper die is removed only when the
liquid metal has cooled. The metal will often come out stronger, with a nicer grain, and less
metallic shrinkage when using this process. Magnesium, aluminium, and their alloys are
typically utilized but many other metals can be employed.

Squeeze casting is a new casting technology that eliminates problems like shrinkage, gas
pore, and cold shut that occur during the solidification process. Some of the most prominent
advantages of the squeeze casting method are improved mechanical qualities, high
dimensional precision, elimination of porosities, and reduced material waste owing to the
lack of a gating mechanism.

There are two forms of squeeze casting:

1. straight direct squeeze casting and

2. no straight indirect squeeze casting.

This technology is used to make low-cost composite components with basic shapes. The
indirect version of this approach is utilized to build common composite components;
however, the manufacturing costs are significant. Automobile components such as front
steering knuckles, chassis frames and brackets, and nodes are made using the squeeze casting
method.

In most casting procedures, two dies are used, but squeeze casting employs the dies in a
unique way. Normally, the two castings are joined and liquid metal is poured into the casing.
A pool of liquid metal is deposited in the bottom die, and a top die comes in and squeezes the
metal into a form using a squeeze cast. Because pressure is exerted via the top die, this is not
technically casting, but rather a hybrid process that incorporates forging.

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This application can only employ liquid metal. While materials like plastic may melt at high
temperatures, this method will not work for casting plastic. Workers wait until the metal is
totally cold after setting the higher die. The top die will be released once the metal has
cooled, and the desired form will have been cast into the now-solid metal.

Because magnesium, aluminium, and metals alloyed with these two elements are quick to
melt and have a wide range of applications, they are commonly employed in squeeze casting.
Almost any metal may be utilized in this technique at the same time. Most low- to medium-
temperature melting metals can be employed unless they are liquid at ambient temperature,
such as mercury, or highly radioactive, such as plutonium. High-temperature melting metals
are frequently unsuitable for casting because they melt the dies or are too difficult to cast
without warping or other problems. Fig. 5. Shows the squeeze casting process.

Fig.5. Squeeze Casting Process

3.1.1. Casting parameters

Casting temperatures are determined by the alloy and the shape of the item. Normally, the
starting point is 6 to 55°C higher than the liquidus temperature.

Tooling temperatures typically range from 190 to 315°C.

Typical pressure levels range from 50 to 140 MPa.

Lubrication When sprayed on the heated dies before to casting, a suitable quality of colloidal
graphite spray lubricant has proven sufficient for aluminium, magnesium, and copper alloys.

3.1.2. Advantages Of Squeeze Casting process

• Provides a wider range of forms and components than other production processes

• Requires little or no post-cast machining

• Low porosity

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• Good surface texture

• Fine microstructures with greater strength components

• There is no waste and all materials are used.

3.1.3. Disadvantages Of Squeeze Casting process

• High costs owing to complicated tooling

• Limited flexibility due to equipment specialized to certain components

• The process must be precisely managed, which slows the cycle time and raises the cost of
the procedure.

• High production quantities are required to justify equipment investment due to high costs.

3.2. Stir casting

A mechanical stirrer is being utilized for making a winder in the grid of material for
consolidating support by the projecting technique mix projecting. This is an innovation for
creating composite materials in which the supported material is blended in with fluid liquid
metal utilizing a mechanical stirrer. The fluid metal lattice composite material is then filled a
form in the customary projecting technique. Numerous factors impact the composite's
attributes and microstructure all through this interaction. As a result of its expense viability,
large scale manufacturing reasonableness, straightforwardness, almost net molding, and
simpler control of composite construction, it is a decent methodology for making metal lattice
composites (Harmeet Singh, Gurinder Singh Brar, Harish Kumar, Vikrant Aggarwal, 2021).

Fig. 6. Schematic of stir casting setup

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A heater, support feeder, and mechanical stirrer make up the mix projecting hardware
portrayed in fig. 6. The heater is utilized to warm materials and soften them. Since fast poring
is essential in the wake of blending the joined slurry to stay away from strong particles
getting comfortable the lower part of the cauldron, the base poring heater is more qualified
for mix projecting. The vortex made by the mechanical stirrer prompts the blending of the
building up materials put into the liquefy. The impeller cutting edge and the mixing pole
make up the stirrer. The impeller cutting edge can have an assortment of shapes and
quantities of edges. Level sharp edges with three numbers are picked on the grounds that they
give a pivotal stream design in the pot while consuming less energy. This stirrer is associated
with variable speed engines, and the stirrer's pivot speed is managed by the engine's
controller. The feeder is additionally associated with the heater and is utilized to take care of
supporting powder into the dissolve. Empty the mixed slurry into a long-lasting mold, a sand
form, or a lost-wax shape.

Fig. 7. portrays the many stages associated with the mix projecting cycle. The framework
material is softened in the base pouring heater during this method. At the same time,
fortifications are warmed at a specific temperature in a different heater to kill dampness,
pollutants, and different impurities. Subsequent to liquefying the framework material to a
specific temperature, mechanical blending is begun to shape a vortex for a specific measure
of time, then, at that point, fortifications particles are poured at a consistent feed rate at the
focal point of the vortex utilizing the feeder gave in the arrangement, and the mixing system
is gone on for a specific measure of time after the fortifications particles have been totally
taken care of. The liquid is then placed into a pre-arranged shape and let to cool normally
prior to setting. Heat treatment, machining, testing, review, and other post-projecting cycles
have likewise been finished. Different impeller edge calculations are accessible. The absolute
first stage in this methodology is to dissolve the framework material.

Melting of matrix Stirring of molten metals Feeding of reinforcement

materials by mechanical stirrer materials

Solidification Pouring of mixture in the Continuous stirring of mixture

mold
(Matrix Reinforcement)

Fig. 7. Process of stir casting

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3.2.1. Advantages Of Stir Casting process

• It is simple, adaptable, and cost-effective

• It is suitable for mass manufacturing

• It has a good matrix-reinforcement interface and forms that are close together

3.2.2. Disadvantages Of Stir Casting process

• Difficulty achieving homogeneity and high porosity

• Possibility of matrix-reinforcement reaction and poor wetting owing to high temperature

Fig. 8. Stir Casting

The stir casting method is designed to generate a homogeneous mixture. Manufacturing
composite material is a simple and low-cost technique. The rotational speed, pouring
temperature, pouring speed, and shape life are basic factors that impact the projecting
characteristics. At very low speeds, increasing the spinning speed of the stirrer above the
intended limit may induce refinement and instability.

To minimize ripping, it is advised that high speed be utilized. The temperature at which the
liquid metal is poured is also significant for its solidification. The liquid metal's high
temperature energizes columnar turn of events, though the low temperature advances high
grain refining. The pouring temperature of the liquid composite material should be
sufficiently high to take into consideration smooth metal stream and keep away from cold
laps. Pouring at a low-speed works with course cementing and brings down the chance of

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tearing, though pouring at a high velocity produces inordinate choppiness and dismissal.
Preheated kicks the bucket produce more refined castings than sand molds despite the fact
that they are simply an optional need for structure creation. By creating metal framework
nano composites utilizing electromagnetic mix projecting, the mechanical mix projecting
strategy was utilized to produce and address unfortunate blending of particles with high
porosity in the matrix (Harmeet Singh, Gurinder Singh Brar, Harish Kumar, Vikrant
Aggarwal, 2021).

To foster novel composites, the conventional dissolve mix process was utilized to create 11
wt.% boron carbide as supported material with an aluminum 6061 Al lattice. At a temperature
of 750°C, the whole course of delivering composite material was found.

3.3. Powder metallurgy

Powder metallurgy is a metal-shaping method where packed metal powders are warmed to
simply underneath their dissolving temperatures. Albeit the procedure has been utilized for
very nearly a long time, it has as of late acquired far reaching acknowledgment as a superior
technique for making excellent parts for a scope of basic applications. This achievement
might be credited to the technique' benefits over other metal framing innovations like
manufacturing and metal projecting, like material usage, shape intricacy, and close net-shape
layered control, among others. Thus, powder metallurgy has procured a standing as a green
innovation.

While delivering composite materials, this approach is more difficult than others. Just at more
noteworthy creation rates is the PM strategy financially savvy. PM includes compacting little
powdered materials in a pass on under high tension to get the necessary structure. The
squeezed part is in this way sintered, giving it extraordinary strength and the thickness, it
requires. Fig. 9. portrays the means engaged with this methodology.

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Metal Secondary Machining

Powders (Original)

Mixing Compaction Sintering Finishing

Secondary Finishing
Additives
(Optional)
Fig. 9. Flow Chart of Powder Metallurgy Process
Equipment, devices, cameras, farming and nursery gear, sports products, modern and
business apparatus, and safeguard hardware are instances of powder metallurgy parts used in
the auto area. Gears, cams, bushings, cylinder rings, interfacing poles, and impellers are
totally made utilizing this technique. Materials frequently used in the PM technique
incorporate iron, copper, aluminum, nickel, titanium, metal, and bronze.

Fig. 10. Powder Metallurgy Process

Hot expulsion strategy has at last been utilized to make boron carbide particles supported
aluminum 2024 combination lattice composites. The composite material was blended
consistently among aluminum and boron carbide, bringing about a high-strength bond and a
hearty macrostructure (A. K. Bodukuria, K. Eswaraiahb, K. Rajendra, V. Sampatha, 2017).

To make Al-SiC-B4C based metal framework composites, powder metallurgy strategies with
sintering of precisely alloyed ball processing were utilized. A convoluted planetary

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transporter for a four-wheel drive force move framework, a helical stuff and tempered steel
edges utilized in laparoscopic careful scissors, a seaward oil stage complex weighing over 6.5
tones, and a steel interfacing pole utilized in V-8 motors are among the photographs in Fig.
10. Powder metallurgy was utilized to make these parts.

3.3.1. Powder Metallurgy Technologies

Powder metallurgy, in actuality, is collection of processes for producing semi-dense and
completely dense components. The planetary carrier seen here was made using a traditional
powder metallurgy method known as press-and-sinter. Metal injection molding (MIM) was
used to make the surgical scissor components, while hot isocratic pressing (HIP) was used to
make the manifold and powder forging was used to make the connecting rod (PF).
Meanwhile, metal additive manufacturing (AM), a relatively recent phenomenon, is gaining
traction. Parts are currently produced using molecule materials other than metal powders
utilizing a few of these PM handling methods, as well as extra systems, for example, splash
shaping, roll compaction, quick hardening, and others. Ceramics, fired strands, and
intermetallic compounds are much of the time utilized in the present refined materials, which
are seldom delivered completely of metals and metal composites. These include:

• Cermet

• intermetallic compounds

• metal lattice composites

• nanostructured materials

• fast prepares

3.3.2. Advantages of powder metallurgy

• Items made by P/M by and large don't need further wrapping up

• There is no wastage of natural substance

• Sensibly complicated shapes can be made

• Various blends of materials can be utilized in P/M items, which are generally difficult to
make. For instance, blending pottery in with metals

• Computerization of P/M cycle is simple when contrasted with other assembling processes

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• It gives properties like porosity and self-oil to the produced parts.

3.3.3. Limitations of powder metallurgy

• Tooling cost is for the most part and must be legitimate in large scale manufacturing

• Unrefined substance cost is exceptionally high

• Mechanical properties of the parts are of bad quality when contrasted with cast or machined
parts

• Now and again, thickness of various pieces of eventual outcome can exceptionally because of
lopsided pressure

• Size of item that can be made is for the most part restricted to 2-20 kgs

3.3.4. Applications of powder metallurgy

• P/M parts are used as filters because of porous nature

• Making cutting instruments and passes on

• Utilized in making apparatus parts

• Because of self-greasing up property P/M parts are broadly utilized in making direction and
hedges

• P/M process is utilized in making magnets

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CHAPTER-4

4. Applications of Metal Matrix Composites (MMCs)

Particularly stir casting, squeezing, and powdered metallurgy are the methods used to form
composite matrix metals. The composite materials are generally used in aerospace
engineering, automobile parts, medical and defense engineering, and more recently on luxury
buses due to the excellent strength and steel properties of MMC materials (Harmeet Singh,
Gurinder Singh Brar, Harish Kumar, Vikrant Aggarwal, 2021).

Continuous efforts in reducing CO2 emissions are becoming increasingly global and this
poses a significant challenge for automotive manufacturers. The main solution for the same
could be reduction in the total weight of the vehicles by using other materials (appropriate
metal matrix compounds) car parts we can decrease 20% -30% of the total body weight of the
vehicles. The metal composite technology is rapidly evolving and will replace conventional
automotive parts manufacturing processes (H.G. Prashantha Kumar, M. Anthony Xavior,
2021)

Metal matrix composites (MMCs) can be used in multiple ways for enhancement of
automobile parts, few of the applications are as mentioned below.

4.1. Piston

The piston is an important part of an internal combustion engine which converts the fuel into
energy. It is a moving component which is used to transfer the force by means of connecting
rod. By using magnesium alloy AZ91 and its MMCs AZ91/1.5WC and AZ91/3.0WC, we
can get weight reduction up to 35% for the selected piston applications. The AZ91 / 3.0WC /
T6 exhibits approximately 70% load-bearing capacity compared to base alloy so that
magnesium-based MMCs are used to replace the air compressor piston application in place
ofAl alloys. Piston casting through magnesium MMCs is manufactured through stir casting
(P. Karuppusamy, K.Lingadurai, V. Sivananth, S. Arulkumar, 2021). Fig. 12 Shows
fabricated piston of alloy AZ91 and composite AZ91/3.0

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Fig. 12. Fabricated AZ91 and AZ91/3.0 MMC Piston

4.2 DISC BRAKE

A disc brake is a type of break that uses brake calipers to compress the disc pad or rotor to
create a collision. Al-AlN-B4C (Al-80%, AlN-10%, B4C-10%) hybrid composite material is
used to design the disc brake because it has better durability and high wear resistance and is
easily available and has quite reasonable price, compared to other materials used. The
material properties of the material during the selection of disc brake material to be considered
are of high thermal conductivity and due to the al-nitride and boron carbide composition ratio
of heat transfer rate is reasonably better compared to other materials (Sasikumar C., Prakash
Kanna G., Sundarsen R., Ramakrishnan A, 2021). Fig. 13. Shows disc brake.

Fig. 13. Disc brake

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4.3. DRIVE SHAFT

A power shaft sends mechanical strength advanced with the aid of using the engine to the rear
wheel via the differential of vehicle. The normal drive shaft is replaced by composite
materials. The composite drive shaft is intended to replace the common metal with titanium,
aluminum and vanadium alloy. This substitution of composite materials for conventional
metal has resulted in a significant degree of weight loss. Polymer matrix composites have the
natural frequency of much lower value when compared to natural frequency of the metal
matrix composites (C. shivkumar,2021). Fig. 14. Shows the diagram of drive shaft.

Engine
Drive Shaft

Transmission
Wheel Differential

Fig. 14. Drive shaft

Fig. 15. Shows the imported model of drive shaft.

Fig. 15. Imported model

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4.3 LEAF SPRING

Leaf spring is one of the oldest and most popular suspensions and is still widely used in
commercial vehicles. The automotive industry is showing interest in replacing steel springs
with composite leaf springs due to high strength to weight ratio because weight loss while
maintaining energy is one of the most important issues. 7075 Al reinforced with 25% B4C
and a carbon epoxy compound is produced by stir cast extraction, used for spring leaves. The
composite leaf spring has a simpler weight compared to the common metal spring with
similar meanings. But there is a problem, the cost of making a composite leaf spring does not
work more than a standard spring leaf spring (Harmeet Singh, Gurinder Singh Brar, 2018).
Fig. 16. Shows the leaf spring.

Fig. 16. Leaf spring

4.5. Crown and pinion

A gear is a device used in a transmission system that transmits rotation power to another gear.
The gear teeth transmit energy without slipping and depending on the material they can
transmit energy at different speeds, torque and in a variety of ways. The standard pinion
crown is modeled on a combination of high-strength (97.5%) and silicon carbide (2.5%)
because it looks better compared to existing materials. The high carbon steel structure and
silicon carbide shows better strength for a larger load with the same pressure (R. Charles
Godwin, C. Dhanasekaran, 2021). Fig. 17. Shows the crown and pinion.

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Fig. 17. Crown and pinion

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CHAPTER-5

RESULT

While reading several research papers, we came to the conclusion that conventional methods
of making parts of automobiles lead to more carbon emissions, which can be rectified by
using several composite materials and by lowering the weights of cars. It has been found that
approximately 20%-30% of the weight of automobiles can be reduced by using metal matrix
composites. Many parts of cars are improvised in order to get better experience and
performance by replacing conventional alloy parts with MMCs. viz. we can reduce the
weight of certain piston applications by up to 35 percent by employing magnesium alloy
AZ91 and its MMCs AZ91/1.5WC and AZ91/3.0WC, MMCs like Al-AlN-B4C (Al-80%,
AlN-10%, B4C-10%) used in disc brakes because it offers superior durability and wear
resistance, is readily accessible, and is very inexpensive when compared to other materials
and Leaf springs are the suspensions which are mostly used in vehicles. They are
conventionally made up of steel but can be replaced by 7075 Al reinforced with 25% B4C
and a carbon epoxy compound MMC in order to get a high strength to weight ratio.

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CHAPTER-6

CONCLUSION

Exploring information from earlier years and current years uncovers that metal lattice
composites have a ton of potential for creating vehicle parts for the car area. With current
mechanical turns of events, various materials are expected with different properties to make
item as indicated by the prerequisite, and present-day innovations offer a wide assortment of
arrangements and rules for choosing materials to the producer of items as per various
applications. As per the examination, interest for eco-friendly and electric vehicles has
flooded in the past five years. The car business is principally centered around the
investigation of metal lattice composite-based vehicle parts to address the requirement for
lightweight and high strength parts. Auto parts made of metal grid composites have a high
strength, obstruction rate, and exhaustion life. The assessment of metal framework composite
parts is critical thus. It is essential to make metal lattice composite vehicle parts producing
methodology, material characteristics, and testing.

The many kinds of materials used in different applications are momentarily talked about.
The key characteristics expected to construct the best metal framework composite are
momentarily referenced, which will help the analyst in their work. The cycles of crush
projecting, powder metallurgy, and mix projecting for delivering composite material have
been completely tended to. The most troublesome part of making metal lattice composites is
accomplishing a homogenous combination. Unique changes to old regular strategies were
important to produce a homogeneous blending of metal grid composite. Metal grid
composites can possibly alter the manner in which vehicle parts are planned, fabricated, and
created. The safeguard, aviation, and electrical designing ventures could profit from new
nano or savvy composite materials. New examination in this subject can possibly change the
whole globe into another lightweight, high-strength material. These composite classes have a
brilliant future in front of them, since the businesses have focused on getting minimal
expense, superior execution MMCs.

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