Review
Carbon fiber reinforced metal matrix composites: Fabrication processes and properties

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Abstract

This paper reviews the research and development works conducted over the past few decades on carbon fiber reinforced metal matrix composites (CFR-MMC). The structure and composition of carbon fiber and its bonding to metal matrix have an impact on the properties of the resulting CFR-MMC remarkably. The research efforts on process optimization and utilizing of carbon fibers are discussed in this review. The effect of carbon fiber on structural, physical and mechanical properties of metal matrix composite are studied as well. This review also provide an overview of the research to date on various fabrication methods that is used for production of CFR-MMC.

Introduction

The advent of technological era has brought the need for new materials to tackle everyday challenges of current materials for different applications. In the quest for new advanced materials, researchers have innovated various material systems. One of the most prominent material systems in the past few decades is Metal Matrix Composites (MMCs), where two or more constituents are used to fabricate a new material [1]. By formulating a composite, it is possible to use the unique advantages of different constituents in a complementary manner to suppress the limitations of each constituent. For example, the need for lightweight structural material for the applications in automotive and aerospace industry is paramount these days. This is partly due to enforcement of new emission regulations and the rising fuel costs. Traditional materials such as aluminum or titanium are failing to overcome current challenges of ordinary materials are facing today. Properties of materials significantly deteriorates at relatively low temperatures and in turn limits their usability in critical components [2]. However, by combining inherent ductility of matrix and toughness with high stiffness and high specific strength materials, such as ceramic filaments or carbon fibers, it is possible to fabricate materials that can overcome performance issues and also being used in high-tech applications like nanoelectronic, structural and medical applications [3], [4], [5], [6], [7], [8], [9], [10], [11], [12]. The incorporation of such reinforcements into metal matrices significantly improves the hardness, tensile strength, elastic modulus and other mechanical properties. Few other properties, such as thermal conductivity (TC), coefficient of thermal expansion (CTE), coefficient of friction, wear resistance, corrosion and fatigue resistance can also be tailored according to application requirements in metal matrix composites [13], [14].

As an example, a heat sink material needs to have high heat dissipation rate in order to provide effective cooling to the electronic chip. At the same time the CTE of the material has to be low so that it generates less thermal stress while undergoing thermal cycles. Pure copper and aluminum has relatively high CTE of 17 × 10−6 and 23 × 10−6/K respectively; thus, generates high thermal stresses [15], [16]. Studies show that silicon carbide (SiC) reinforced MMCs can provide high heat dissipation rate and minimal thermal stresses due to low CTE mismatch [17], [18], [19], [20]. Diamond particle reinforced copper MMCs has also been studied to replace bulk metal heat sinks [21], [22], [23]. Although, these MMCs were found to have improved thermo-mechanical properties, the required volume fraction of the reinforcement for property enhancement is as high as 60%. This in turn makes the diamond and SiC reinforced MMCs very difficult to machine for industrial applications. In search of the balance between machinability and thermo-mechanical properties, Carbon fibers (CFs) reinforced MMCs have also been explored for heat sink application. Lalet et al. [24] reported that only 30% carbon fiber reinforcement could reduce the CTE of aluminum and copper. Owing to the very low CTE in the longitudinal direction (−1 × 10−6/K) CF reinforced aluminum and copper MMCs has been found to offer great promise as heat sink material [24], [25], [26], [27], [28], [29]. As mentioned earlier, carbon fiber reinforced metal matrix composites also possesses high wear resistance, and thus found application in bearings and wear parts [30]. Liu et al. [31] reported that, 40 vol% of short CFs not only improves the wear resistance of Cu, but also improves the friction coefficient. Owing to the high temperature strength and self-lubricating effect of CFs [32], [33], [34], other chemical and physical properties such as, modulus, strength, toughness, electrical conductivities of these MMCs also tend to be superior [30], [35], [36], [37], [38], [39], [40]. As a result, CF-MMCs has received great attention from the aircraft, aerospace, automobile and electronics industries [41], [42], [43].

In essence, pure metals and traditional metallic alloys are often inadequate to provide advanced properties in complex applications. This has led to the discovery of composites with specifically tailored properties for a certain application. Many real world applications are already benefiting from the use of metal matrix composites. Few notable applications of MMCs include power electronics modules, multi-chip modules, automotive engine cylinders, disk brakes and drive shafts and F-16’s system that uses monofilament silicon carbide as a filler in titanium matrix for a structural component of the jet’s landing gear.

Although, the field of metal matrix composites is not entirely new, but understanding of this metal based composite system is far from complete. This is especially true for fiber reinforced metal matrix composites. Table 1 list of review articles published after 2000 in the field of MMC.

It is interesting to note that, only a handful of review articles has been published in the field of fiber reinforced MMCs. As carbon fiber is one of the most promising reinforcements, a review article discussing about the current state-of-the-art in this area is required. This will not only serve as a report to summarize the current state of knowledge on carbon fiber reinforced metal matrix composites, but also can provide direction for future research and development in this field by creating an understanding of the topic

Section snippets

Characteristics of metal matrix composites

The final performance of a metal matrix composite depend upon three key factors consisting of the matrix, the reinforcement, and the matrix/reinforcement interface [44], [45], [46], [47], [48]. Matrix is the continuous phase that its properties are being improved by the incorporation of the reinforcements. Different metallic matrix have been used for fabrication of carbon fiber reinforced metal matrix composite based on their ultimate mechanical performance, simplicity and application (Table 2).

History, synthesis and properties of carbon fibers

Carbon is arguably the most amazing element in the nature. An astounding number of different structures at different length scale can be obtained by tailoring carbon structure [55], [56], [57]. Extensive research has led to the synthesis of different forms of carbon-based materials, such as graphene, carbon fiber, fullerenes and nanotubes [58], [59], [60], [61], [62]. The diversified morphology of different carbon-based materials, its availability and the flexibility of modifying physical

Surface treatment and sizing of carbon fibers

Carbon fibers are designed to be used mainly in a matrix and help transferring the stress away from matrix in order to improve mechanical properties of composite structures [78]. During carbonization process most of the non-carbonaceous elements are removed and only carbon remains in fibers. Presenting carbon atoms results in a strong and chemically stable fiber. However, carbon atoms in graphite or disordered arrangement have a weak interaction with all kinds of known matrices [63]. A weak

Fabrication processes of carbon fiber reinforced metal matrix composites

Extensive research has been carried out to investigate the potential of carbon fiber as reinforcement materials for metal matrix composites. The main objective of CF reinforced MMCs (CF-MMCs) is to develop a range of materials with the following characteristics:

  • High strength, lightweight materials.

  • Improved thermal properties. i.e., reduced coefficient of thermal expansion and increased thermal conductivity.

  • Improved mechanical properties. i.e., specific strength, elastic modulus, etc.

  • Improved

Concluding remarks

  • Carbon fiber reinforced metal matrix composites possess a great potential to replace existing unreinforced metals and alloys in aerospace, automobiles, and petrochemical industries. The carbon fiber reinforced metal matrix composites provide excellent strength and mechanical performance, ease of manufacturing technique, excellent thermal and electrical properties, enhanced wear/corrosion resistance and reduced coefficient of friction making CF-MMCs appropriate for a variety of engineering

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