Materials and Manufacturing Processes

ISSN: 1042-6914 (Print) 1532-2475 (Online) Journal homepage: http://www.tandfonline.com/loi/lmmp20

Fabrication and Machining of Metal Matrix

Composites: A Review

Preetkanwal Singh Bains, Sarabjeet Singh Sidhu & H. S. Payal

To cite this article: Preetkanwal Singh Bains, Sarabjeet Singh Sidhu & H. S. Payal (2016)
Fabrication and Machining of Metal Matrix Composites: A Review, Materials and Manufacturing
Processes, 31:5, 553-573, DOI: 10.1080/10426914.2015.1025976

To link to this article: http://dx.doi.org/10.1080/10426914.2015.1025976

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Materials and Manufacturing Processes, 31: 553573, 2016
Copyright # Taylor & Francis Group, LLC
ISSN: 1042-6914 print=1532-2475 online
DOI: 10.1080/10426914.2015.1025976

Fabrication and Machining of Metal Matrix Composites: A Review

Preetkanwal Singh Bains1, Sarabjeet Singh Sidhu2, and H. S. Payal3
1
IKG Punjab Technical University, Kapurthala, India
2
Department of Mechanical Engineering, BCET, Gurdaspur, Punjab, India
3
Department of Mechanical Engineering, St. Soldier Institute of Engineering and Technology, Jalandhar, Punjab, India

Intrinsically smart, metal matrix composites (MMCs) are lightweight and high-performance materials having ever expanding industrial
applications. The structural and the functional properties of these materials can be altered as per the industrial demands. The process
technologies indulged in fabrication and machining of these materials attract the researchers and industrial community. Hybrid electric
discharge machining is a promising and the most reliable nonconventional machining process for MMCs. It exhibits higher competence
for machining complex shapes with greater accuracy. This paper presents an up-to-date review of progress and benets of different routes
for fabrication and machining of composites. It reports certain practical analysis and research ndings including various issues on
fabrication and machining of MMCs. It is concluded that polycrystalline tools and diamond-coated tools are best suitable for various
conventional machining operations. High speed, small depth of cut and low feed rate are a key to better nish. In addition, hybrid electrical
discharge machining has proved to be an active research area in critical as well as nonconventional machining since last few years. This paper
incorporates year-wise research work done in fabrication, conventional machining, nonconventional machining, and hybrid machining of
MMCs. Conclusions and future scope are addressed in the last section of the paper.

Keywords Composites; Conventional; Machining; Matrix; Metal; Nonconventional.

INTRODUCTION coefcient of thermal expansion with higher strength

Metal matrix composites (MMCs) are the materials
with less density and higher specic properties such as
strength and stiffness. These materials are combinations
of two or more materials, exhibiting properties that
are hard to obtain from a single material otherwise. In
these combinations, one material acts as a matrix and
the other acts as reinforcement. The matrix material
distributes the stress applied over it to the reinforcement
constituents which also protects and gives shape to the
matrix material. The reinforcement provides the desired
mechanical strength to the composite material in a pref-
erential direction. The reinforcement is in the form of
wires, whiskers or particulates, continuous=discontinu-
continuous bers that are distributed in different
volume fraction percentages according to their proper-
ties. Except the reinforcements that are in the form of
wires, others are provided of ceramics that are oxides,
carbides, and nitrides having excellent properties like
specic strength and stiffness at both high and ambient
temperatures as described by Callister [1]. It is possible
to tailor their properties as per the requirement of
various industrial applications by suitable combinations
of matrix, reinforcement, and fabrication method.
These reinforcements are known for their lower
Received January 7, 2015; Accepted March 3, 2015
Address correspondence to Preetkanwal Singh Bains, Research
Scholar, IKG Punjab Technical University, Kapurthala, India;
E-mail: preetbains84@gmail.com
Color versions of one or more of the gures in the article can be
found online at www.tandfonline.com/lmmp.
and modulus. According to Marsh [2], the automotive
industry is facing continuous pressures to develop
fuel-efcient, less polluting vehicles. As a result, the
industry has switched over to ber reinforced compo-
sites from expensive alloy materials to make its products
light in weight and environmentally friendly.
The matrices like aluminum, magnesium, steel, etc. are
mostly preferred as a potential material for composites.
The brittleness in the form of reinforcement and the
ductility in the form of a matrix are required in a good
MMC. Titanium can also be used as a matrix where
high-temperature applications are required. The conven-
tional reinforcements used are SiC, Si3N4, AlN, Al2O3,
TiB2, ZrO2, and Y2O3. Matthews and Rawlings [3],
Surappa [4], and Waku and Nagasawa [5] found out that
MMCs possess several advantages over monolithic
materials. These include greater strength, higher stiff-
ness, light weight, better high-temperature properties,
low coefcient of thermal expansion, improved electrical
performance, better abrasion, and wear resistance. How-
ever, on the other side, toughness of MMCs is inferior as
compared to monolithic metals, and moreover the latter
are comparatively more expensive.
This paper reviews the conventional machining as
well as the nonconventional machining of MMCs and
various other methods to fabricate them.
FABRICATION METHODS
Development of fabrication processes for the pro-
duction of high-performance composites has been
reported in many research studies. Figure 2 illustrates

553
554
FIGURE 1.Schematic diagram of processing steps for the manufacture of powder metallurgy composites [17]. # Elsevier. Reproduced by permission of
Elsevier. Permission to reuse must be obtained from the rightsholder.
various fabrication techniques that were in use for the
last few years. The following methods are most common
for fabrication of the MMCs at large-scale industrial
level.
1. Solid-phase processes.
2. Liquid-phase processes.
The adoption of the route for the synthesis of MMCs
depended on many factors including the matrix temp-
erature during processing, extent and reinforcement
loading, and desired degree of microstructural integrity.
FIGURE 2.Research studies conducted on fabrication routes of MMCs
for the last 10 years.
P. SINGH BAINS ET AL.
Well-established methods in solid-state processes include
blending of powder followed by isostatic pressing
(powder metallurgy (PM) processing), spray deposition
techniques, and diffusion bonding. Melt stir casting,
melt inltration, spray casting, and in situ (reactive)
processing come from liquid-state processing.
In the PM technique, dry or liquid suspended powder
is blended that is followed by hot isostatic pressing
(HIP), cold compaction, canning, degassing, etc. There
are a few composites that can be fabricated by the PM
technique alone, as quoted by Hehmann and Froes [6].
In the PM method, the constituents are mixed into
solid-state diffusion, and sintering gives desired shape
to the composite. In spray deposition technique for com-
posite fabrication, each individual ber providing
reinforcement is coated along with the matrix material
followed by diffusion bonding. The MMC thus
fabricated possesses more homogeneous microstructure
compared to those fabricated by the cast technique. In
conferences held in the UK, Willis et al. [7] and
Miller et al. [8] had already supported it as the best
suitable technique for fabrication of reinforced and
un-reinforced alloys. It provides even distribution of
the reinforcement in a matrix that is 9598% dense. Melt
stir casting method or the vortex technique involves
incorporation of a reinforcing agent (particula-
te=whisker) into liquid matrix melt, stirring it with rotat-
ing impeller and allowing the mixture to solidify. In
inltration process, preform of bers=whisker is made
and is inltrated by melt thus allowing mixing of liquid
metal (partial or full) with reinforcement. Sanchez et al.
FABRICATION AND MACHINING OF METAL MATRIX COMPOSITES
[9] confers the inltration technique to be an appropriate
method for the fabrication of MMC, wherein preforms
made of a reinforcing agent were lled with the alumi-
num matrix. Sidhu et al. [10] in their review tried to
show the glimpses of stir casting process, pressurized
liquid inltration, and plasma spray decomposition
methods of fabrication of MMCs. Apart from this, they
touched upon the PM technique for fabrication of
composites to some extent. In their study, the authors
revealed the fabrication of MMC with Al as the matrix
component and SiC as the reinforcement agent because
of ductility and low density of aluminum. For high-
temperature applications, Al was replaced by titanium
despite its high density and brittleness. In inltration
process, the reinforcing member, that is, SiC is kept as
preform that is held intact with the help of silica or
alumina as binders. The liquid matrix, that is, Al is
compressed against preform with the assistance of piston
cylinder arrangement. Rosso [11] discussed various
methods to fabricate ceramics and MMCs and their
related properties along with the applications and future
prospects of such materials. He prepared the cylindrical
samples of the powders compacted with a pressure of
200300 MPa. Few samples were pre-sintered and
machined afterwards, while the others underwent direct
mechanical operations and then sintered to examine the
effect of sintering on the machining of powders. The
powders were sintered for 1 hour at a temperature of
1600 C in the air. The PM technique, compared to other
fabrication techniques, is a promising and versatile
method for the fabrication of a composite. It ensures
better mechanical and structural properties of the com-
posites along with high homogeneity. Jha et al. [12] while
synthesis and characterization revealed the effect of
sintering temperature, time, and composition of the con-
stituents on the microstructure, hardness, and density of
FeZrO2 MMC. The formation of Zr6Fe3O phase had
been noticed in X-ray diffraction (XRD) analysis as a
result of partial reaction between Fe and ZrO2 and this
phase increases with ZrO2 content. The microstructure
witnessed the dispersion of Fe, ZrO2, and a small
amount of Zr6Fe3O along with some minor impurities
in the form of carbon. The density decreases with a per-
centage increase of ZrO2. The hardness of the samples
also varies with sintering temperature as explored by
them. Phase formation due to partial reaction has also
been reported by Konopka and Ozieblo [13]. They inves-
tigated the formation of FeAl2O4 spinel phase during
the sintering process employed in the fabrication of
FeAl2O3 as MMC by the PM technique. Pagounis
et al. [14] fabricated ceramic composite by HIP tech-
nique using high chromium white iron powder as matrix
and Al2O3, TiC, and Cr3C2 as reinforcements. The inves-
tigations revealed that the interface between matrix and
reinforcement in the ironalloy matrix had an effect on
the amount of martensitic transformation. Moreover,
no effect on the wear resistance and hardness were
noticed; however, toughness deteriorated to a great
extent with a weak interface. Zadra and Girardini [15]
discussed the possibility of obtaining titanium MMCs
555
with discontinuous reinforcement by mechanical alloying
and sintering. This process was followed by in situ
precipitation of titanium carbide. They also discussed
the ex situ routes for the same. The titanium sponge
and carbon black as expected raw materials, and
calcium as a process control agent, could be an alterna-
tive to high-cost titanium metal without compromising
the mechanical properties of the material. A high plastic
deformation can be seen before breaking at 1013 MPa
with a strain at fracture of 5%. This study revealed
certain facts about MMCs. For instance, the small size
of reinforced particles provides better mechanical
properties and thermal stability, while large size and high
volume of reinforcement give better wear resistance. The
PM technique adopted in this study proved to be the best
method of MMC fabrication as no other by-product or
unwanted layer is formed between reinforcement and
matrix. The process accompanies the mechanical alloy-
ing in which calcium is used as process control agent.
The ne titanium powder with little nitrogen and oxygen
content was obtained. Tin was added to avoid the cold
welding phenomena. Carbon addition results in the
formation of titanium carbide that increases with an
increase in carbon content. Similarly, aluminum can be
added to obtain titanium aluminides having even higher
thermal resistance as explained by Mu~ noz-Moreno et al.
[16]. Afterwards, the powder is sintered by spark plasma
technique to obtain sufciently dense samples. It was
observed that the average particle size increases after
sintering but not beyond micron size. X-ray analysis
followed sintering was performed wherein only phases
of titanium, a and b and Titanium carbide were
detected. For both alloys, no intermetallic TiCr or other
phases were observed. Samples with good toughness
and those withstanding plastic deformation in addition
to high ultimate tensile strength (UTS) and yield
strength (YS) can be witnessed. Harrigan [17] reviewed
and described various patents that were obtained while
MMCs were fabricated by the PM processing
techniques. He explained the method of cold isostatic
pressing (CIP) vacuum sintering process (Fig. 1) while
fabricating the Al=B4C MMC, reinforced by boron car-
bide, also known as Boralyn composites. This process
of composites manufacturing involves lesser cost and
smaller process losses, thus lower nished product cost.
Moreover, the mechanical properties of composites thus
manufactured are similar to those manufactured by
vacuum hot pressing. Moustafa et al. [18] investigated
the process of MMC fabrication by the PM technique.
The authors explained the process of fabrication of
Cu-based matrix reinforced with SiC (Ni coated and
uncoated) and Al2O3 (Ni coated and uncoated). They
revealed that uncoated SiC and Al2O3 reinforced
composites swell when sintered while composite with Ni
coated SiC reinforcement shrinks when sintered. Ni
coated reinforced composites exhibited higher relative
density and lower porosity. The YS and compressive
strength of composites with Ni coated reinforcement
was also found to be superior as compared to
composites with the uncoated reinforcement.
556
In stir casting process, the matrix is heated above
melting temperature and stirred followed by the
addition of reinforcement material into the vortex.
But this technique of fabrication is not that reliable
due to the non-homogeneity of the constituents. In
the plasma spray technique, the matrix and the
reinforce material are decomposed by the spraying
method. But this approach contributes toward increas-
ing in cost of fabrication of MMC. Lai and Chung [19]
noticed that SiC reacts with Al at higher temperature
and forms aluminum carbide, which is brittle in nature
and tends to weaken the composite affecting the mech-
anical properties of the same. The chemical reaction for
the same is as follows:
4Al SiC ! Al4 C3 3Si
Further, they proposed surface modication techniques
as a solution to this problem.
In inltration method, excess interfacial reactions are
less due to reduced contact time between matrix and
reinforcement, which otherwise leads to weakening of
composite. Coating of reinforcement is no more required
by this process. Schobel et al. [20] enlisted certain limita-
tions of this process. According to them, voids formation
is a common phenomenon while inltration of particle
reinforced metals. The coefcient of thermal expansion
between matrix and reinforcement being different and
high particle volume fractions are the reasons behind
the formation of voids.
In the abovementioned techniques, the reinforcement is
often prepared separately before composite fabrication.
These techniques are also known as ex situ methods. In
situ processing techniques involve the development of
the reinforcing agent in a metallic matrix with the help
of chemical reactions between different elements or
element and compound. Kayikci and Savas [21] discussed
the centrifugal casting technique, also known as in situ
technique, for fabrication of functionally graded Al=AlB2
MMC. In this fabrication study, boron oxide (B2O3), as a
boron source, has been dissolved in liquid Al at 1400 C
and MMC is fabricated. The resultant composite wit-
nesses two distinct zones, the inner one has almost nil
traces of boron and the outer one has almost 11% boron
as reinforcing agent. UTS and YSs of Al were increased
signicantly by addition of AlB2 akes. UTS and YS
increase further by replacing matrices part by AlSi,
AlCu, and Al. Apart from this, the external zone also
shows higher hardness as compared to internal region.
As far as the fracture is concerned, the external zone
justied good bonding between matrix and reinforcement
without any traces of de-cohesion accompanied by the
brittle fracture in the external zone and ductile fracture
in internal zone. In situ technique is considered to be more
advantageous as compared to ex situ technique because
MMCs fabricated with the former have good wettability
along with homogeneous distribution. The reinforcement
produced by this method exhibits more thermodynamic
stability with matrix hence it is suitable for high-
temperature use.
P. SINGH BAINS ET AL.
Manna et al. [22] discussed the melt stirring
technique and employed it in the fabrication of
AlAl2O3=Grp MMC. Particulate ber is used as
reinforcement media in this fabrication process,
because of its isotropic properties compared to long
bers. Since the mechanical properties of composites
depend on the composition, size, volume fraction, and
the method of fabrication, homogeneity of the two
members is signicantly required. One can conclude
from this study that impact strength of Al 6070 matrix
decreases with the addition of Al2O3 reinforcement,
because of the brittle nature of the later. The hardness
of Al=Al2O3 MMC increases with the addition Al2O3
reinforcement. The hardness of Al=Grp is found to
decline initially with the addition of 5% vol of Gr par-
ticulate. Later on, it improves with 10% and 15% vol
addition of Gr. Moreover, UTS decreases with the
addition of Al2O3 and Gr particulates.
Melt stir casting technique is the simplest of various
methods involved in the fabrication of particle
reinforced MMCs. This process ensures interdendritic
particle trapping that provides a better distribution of
reinforcement. Excellent wetting properties between
matrix and reinforcement are required. It is worth
noting that the particle distribution through the casting
varies as there is the change in cooling rate from the
surface to the center. The melt inltration process of
fabricating MMC involves the injection of liquid matrix
alloy, with or without the application of pressure or
vacuum, into the interstices of the porous preforms of
reinforcement.
There is no second thought that various other fabri-
cation techniques exhibit much higher and unmatched
effort in the development of composites. The high cost,
less adaptability, and an inability to secondary forming
process limits their use. The last few decades witnessed
the recognition of PM process in a variety of applica-
tions, despite its existence for more than 100 years.
Harris [23] has compared results obtained from the
PM technique with those obtained from other fabri-
cation methods. The results obtained are presented in
Table 1. Although the fabrication of MMCs by liquid
metal processing is being paid a considerable attention
because of its low cost, yet it suffers from certain draw-
backs. The distribution of ceramic particles or bers is
nonuniform due to the agglomeration and dendritic
segregation. Second, undesirable chemical reaction at
the interface is caused due to the high temperature of
the melt. Undoubtedly, the PM technique has been
the prominent one. In addition to traditional manufac-
turing methods, some of the critical fabrication techni-
ques (Table 2) need further attention and investigations
to prove their utilization in the future. Some of the new
methods that turn out to be the most promising as a
fabrication methods are molecular level mixing,
CIP-HIP sintering technology, and sputtering method.
These methods can provide, but are not limited to,
clean environment along with excellent impurity
control ensuring good homogeneity of the deposited
matrix.
FABRICATION AND MACHINING OF METAL MATRIX COMPOSITES 557
TABLE 1. Tensile properties different Al MMCs [22].

Youngs modulus 0.2%PS UTS Elongation Fracture toughness

p
Material Fabrication method (GPa) (MPa) (MPa) (%) (MPa m)

AlCu Squeeze cast 70.5 174 261 14.0

Al-Cu Al2O3 (Vf 0.2 ber) Squeeze cast 95.4 238 374 2.2
AlCuMg (T6) (2014) Spray formed sheet 73.8 432 482 10.2
Al-Cu-Mg SiC (T6), (Vf 0.1,10 mm particle) Spray formed sheet 93.8 437 484 6.9
AlCuMg (T4) (2124) Powder rolled plate 72.4 360 525 11.0
Al-Cu-Mg SiC (T4),(Vf 0.17, 3 mm Powder rolled plate 99.3 420 610 8.0 18
particle)
AlCuMg (T6), (2124) Powder rolled plate 73.1 425 474 8.0 26
Al-Cu-Mg SiC (T6),(Vf 0.17, 3 mm Powder rolled plate 99.6 510 590 4.0 17
particle)
AlSiMg (T6), (6061) Spray rolled sheet 69.0 240 264 12.3
Al-Si-Mg SiC (T6),Vf 0.1, 10 mm particle Spray rolled sheet 91.9 321 343 3.8
AlZnMgCu (T6), (7075) Spray formed 71.1 617 659 11.3
extrusion
Al-Zn-Mg-Cu SiC (T6),(Vf 0.12, 10 mm Spray formed 92.2 597 646 2.6
particle) extrusion
AlLiCuMg (T6), (8090) Spray formed sheet 79.5 420 505 6.5 38
Al-Li-Cu-Mg SiC (T6), (Vf 0.17, 3 mm Spray formed sheet 104.5 510 550 2.0
particle)

TABLE 2. MMC fabrication categories.

Composite type=process Examples (reinforcement=matrix) Main features

Solid-state processing Al2O3= SiO2 BeO particulate in Cu or Ag Modest strength improvement

a. Insitu forming - Good electrical conductivity
- internal oxidation
b. Powder forming Al2O3 particulate=Al matrix Moderate strength and stiffness to around 300 C
- sintered aluminum powder - Low density
- long or short bers or particulate Al2O3= SiC in Al alloy matrices Good stiffness=strength to modest particulate
incorporated by powder metallurgy incorporated temperatures
- Low density
- Low thermal expansion
Mechanical alloying oxide particles in super alloy matrix - High performance alloy
- High strength at high temperature
c. Diffusion bonding SiC bers in Ti3Al etc. Some problems over oxidation at high temperature
- long bers in intermetallics
Liquid-state processing SiC or Al2O3=light alloy matrices Modest improvements in properties
a. Molten metal mix processing
b. Inltration of performs SiC whisker, Al2O3 bers=Al alloys C=Al and -Good stiffness and strength to 200 C
Mg alloys SiC=Ti alloys B=Al alloys -Low density
-Low thermal conductivity
c. Dispersion various ceramic dispersoids into the melt Some problems in controlling the microstructure
Semisolid processing Si in Al -Modest strength
-Good wear characteristics
d. Spraying particulate=short or long bers in alloy  -Good stiffness and strength
matrices, for example, SiC or Al2O3=in Al alloy -Low density
-Low thermal expansion coefcient
e. In situ processing TiB2 particulate=Al alloy Good strength ductility and toughness
- Fatigue resistant
Other techniques Carbon nanotubes (CNTs) reinforced copper -No clustering of molecules
Molecular level mixing (Cu) matrix nanocomposites -Uniform dispersion
a. CIPHIP TiCp particulate=Al alloy -Formation of oxidation
Constraint of high temperature use
-Microstructure modication
c. Sputtering method titanium aluminide alloy, TiAlNb, on short-length - Clean environment with excellent impurity control
SiC bers - Good repeatability=reproducibility
- Homogeneity of the deposited matrix
558
CONVENTIONAL MACHINING
During machining of MMCs, many reinforcement
materials are found to be harder as compared to most
commonly used carbide and high-speed steel (HSS) tools,
says Ramrattan et al. [24]. Hence, the conventional
machining of MMCs put forward a crucial challenge.
Conventionally, these materials can be machined by
processes like turning, drilling, or milling, with proper
tool design and under proper operating conditions. How-
ever, the reinforcement causes rapid abrasive wear of tool
material hence result in poor machinability and cost
addition. A review report in compliance with machining
and the various issues involved in it is presented.
Manna and Bhattacharyya [25] in their study high-
lighted the use of different tooling systems for the
machining of SiC reinforced Al-based MMC. They were
namely xed rhombic tooling (FRT), xed circular tool-
ing (FCT), rotary circular tooling (RCT), and xed
square tooling (FST). For each tooling system, the inu-
ence of various parameters on tool wear and surface nish
has been observed. They noticed that among all the four
tooling systems, RCT exhibited superior wear resistance
during conventional turning of MMC, whereas the other
three systems showed rapid tool wear. Further, it was also
concluded that approximate tool life of RCT is
signicantly higher compared to other variants.
Effect of Cutting Speed, Feed, and Depth of Cut
Mostly, cutting speed does not have direct impact on
cutting forces while machining of MMCs, according to
Coelho [26]. During machining of various MMCs,
built-up edges (BUEs) have been noticed by many
researchers at low cutting speeds [2729]. Due to these
BUEs, cutting force at low cutting speed is lower compare
to that at high cutting speed. The formation of BUEs
has been investigated by Manna and Bhattacharyya [30]
while machining of SiC reinforced Al matrix composite
and they evaluated the consequence of cutting speed
and feed on ank wear while turning operation using
FRT. The effects of cutting speed, feed rate, and depth
of cut on wear of the tool and BUEs were analyzed.
The results showed that at high speed and low depth of
cut, no BUEs were seen. The BUEs increase the actual
rake angle while machining of MMC at low cutting speed.
A particular range of cutting speed (60150 m=min), low
feed rate, and small depth of cut were recommended for
proper machining. The cutting force at lower cutting
speed is lower compared to at higher cutting speed, due
to the formation of BUEs. The chip formation, a shear
process that involves plastic deformation, can affect the
surface nish, accuracy of workpiece, and tool life. Simi-
lar work has been reported by Hung et al. [31] wherein
they studied and compared different chip formation
phenomena while machining of both monolithic and par-
ticle reinforced MMCs. Lin et al. [32] studied the chip
forming mechanism while machining of SiC reinforced
Al matrix composite at three different speeds. The
addition of SiC resulted in a decrease in the ductility of
the matrix and the formation of semi-continuous types
P. SINGH BAINS ET AL.
of chips. Hence, SiC not only gives strength to the com-
posite but also gives better chip control that is very help-
ful in machining. During chip breaking phenomenon, due
to high shear stress, cracks were initiated from the outer
surface of the chip. Also, some voids were observed
because of particle separation due to stress concentration
at the edges. These voids accelerate the crack growth
along the shear plane.
Although the cutting speed increases the surface nish
to some extent but the rise in temperature of the tool
softens it and affects the tool life to a great deal.
Although the surface roughness does not have a direct
impact on cutting speed, yet the same is affected by
the reinforcement size and feed as quoted by Davim
[33]. The feed, on the other hand, has a greater inuence
on cutting forces. Cutting forces varies directly with
feed. El-Gallab and Sklad [34] concluded that evolution
of high cutting forces due to high feed results in the
initiation of voids around the SiC particles, resulting
in the failure of composite in the form of microcracks.
Depth of cut is also a prominent factor that demands
analysis while machining of MMCs. According to Ciftci
et al. [35], depth of cut inversely affects the surface nish
while machining. Chambers [37] found deterioration in
tool life with the increase in depth of cut.
Among the different tool materials, polycrystalline
diamond (PCD) tool, chemical vapor depositions
(CVDs), cubic boron nitride (CBN), tungsten carbide
(WC), silicon nitride, alumina, etc. are mostly used for
machining of composites. Several researchers [28, 34,
36, 38] have clearly indicated that the PCD tools are
far better than carbide and coated carbide tools and
are the only alternative to the machining of MMCs in
order to have better tool life and enhanced machinabil-
ity. This wear mechanism leads to extensive tool wear.
As shown in Fig. 3 and explained by Weinert et al.
[42] excessive tool wear is noticed that can be overcome
only by using harder cutting tools like PCD tools. Since,
PCD tools are comparatively costlier, hence TiAlN or
diamond coatings can be seen as the alternative. Carbide
tools are mostly preferred over ceramic tools. However,
these tool materials are chemically nonreactive to the
workpiece material. Normally, high amount of tool wear
is observed while machining with carbide tools. At low
cutting speed and high feed rates, carbide tools give
maximum efciency in terms of tool life, as reported
by Kannan and Kishawy [39]. Research proved that
coated carbide tools show superior performance while
cutting of composites as compared to uncoated carbide
tools. Basavarajappa et al. [40] showed a concern with
the surface roughness variation along with surface and
subsurface deformation while drilling of Al=SiC=Grp
MMC. While drilling, carbide and coated carbide tools
were used. It had been concluded that the tool wear
has a strong inuence on feed force and surface rough-
ness. The hybrid MMCs have higher surface roughness
compared to other MMCs. The increase in cutting speed
decreases the surface roughness that otherwise increases
with an increase in feed rate. Moreover, coated carbide
tools gave better performance than multifaceted carbide
FABRICATION AND MACHINING OF METAL MATRIX COMPOSITES
FIGURE 3.SEM of worn-out cemented carbide tool while drilling of (a) Al2O3 short ber reinforced (b) SiC particle reinforced Mg alloys [42].
tools in terms of surface roughness. However, micro-
cracks, particle pullout, and shear of particles were
witnessed while analyzing drilled holes. Ciftci et al. [35]
reported the investigations wherein melt-squeezed cast
MMC with different particle sizes of SiC reinforcement
had been fabricated and machined. The machining was
done by both uncoated and carbide-coated tools by
varying the speed but at constant feed and depth of
cut. The performance of carbide-coated tools was better.
Meanwhile, the effects of cutting speed and tool coating
on surface roughness and tool wear were analyzed, and
it was found out that the uncoated tools gave better sur-
face nish at low speed. The edge chipping was found to
be responsible for poorer surface nish at higher speeds.
The tool life was remarkably affected by the particle size
and weight of SiC as reinforcement accompanied by the
cutting speed. Andrewes et al. [41] investigated the
machining of SiC reinforced MMC by PCD and CVD
diamond coated tools. Further, they added that the
ank wear determines the tool life and the crater wear,
which is very much common in machining of steel, was
not observed. The results justied that the rapid ank
wear of CVD tool was the consequence of adhesive
and abrasive wear mechanisms. The ank wear was
the after effect of the adhesion of an aluminum lm on
cutting tool and abrasion of SiC particles while cutting.
Weinert et al. [42] and Weinert and Konig [43] while
machining of MMCs observed that tool wear results in
an increase in production cost. Moreover, abrasion is
the primary cause of wear that is generated by particles
sliding over rake. They further concluded that CVD
coated diamond tools are far better than PCD tools
and are a good choice for cutting of MMCs as far as
hardness is concerned despite its high cost. Ferreira
559
et al. [44] studied the performance of different tool mate-
rials including cemented carbide, ceramics, CBN, and
diamond (PCD) while turning of composites. They justi-
ed that only diamond tools were best suited for this
process in terms of performance. Further, it was con-
cluded that with an increase in cutting speed, the surface
roughness decreases and increases with an increase in
feed rate. Paulo and Monteiro [45] studied the relation-
ship among cutting forces and tool wear. While machin-
ing (turning and drilling) of Al=SiC MMC using PCD
tool, the tool life is deteriorated by the ank wear
instead of the crater wear that otherwise is encountered
commonly while machining of steels. Sahin et al. [29]
explained the machinability of 2024 aluminum alloy
reinforced with different ratios of Al2O3 at different cut-
ting conditions and cutting speeds by TiN coated car-
bide tool and TP30 coated carbide tool. These coatings
on the tools augmented the tool life that is higher in case
of TiN coated carbide tool. The tool life deteriorates
with the increase in cutting speed for both of the tools.
Major wear form for both the tools was primarily
rounding of nose and ank wear. Teti [46] presented a
detailed summary of conventional machining of some
of the prominent composite materials. Komanduri [47]
and Hung et al. [48] justied enough reasons to support
that the conventional machining of MMCs is not in any
way similar to machining of other metals and alloys. As
because tool faces matrix and reinforcement alterna-
tively while machining, it becomes necessary to adopt
correct mechanism and cutting tool.
Although controversy arises in stating the exact
mechanism of the tool wear, it needs further research
so as to improve the economics and performance of cut-
ting process. According to Coppini and Ferreira [49], as
560 P. SINGH BAINS ET AL.

FIGURE 4.Results of drilling experiments in machining of MMCs [53]. # Elsevier. Reproduced by permission of Elsevier. Permission to reuse must be
obtained from the rightsholder.

far as machining of composites is concerned, negligible Jawaid et al. [55] concluded that with an increase in cut-
amount machining data is available in tool manufac- ting speed, tool wear increases along with a decrease in
turers catalogs as compared to conventional machining thrust force. Songmene and Balazinski [56, 57] per-
of metals. Hence, the optimization of cutting conditions formed dry drilling using HSS twist drill to test the
is crucial, and it has been a tedious task for researchers machinability of newly introduced MMC of Al matrix
so far. with nickel coated graphite and ceramic particles
Turning: Although turning is a very typical machining (GrA-Ni1). This new MMC possessed better machin-
process, many contentious issues have been depicted by ability than any other SiC reinforced MMCs such as
the researchers. Hung et al. [50] investigated the turning Al-9Si.20SiC due to reason that ceramic and graphite
of MMC with CBN, PDC, WC, and DCC tools. Chen particles found in GrA-Ni1 are not that hard as the
and Hoshi [27] observed that cutting speed and tempera- SiC and Al2O3 in other MMCs. Also, as explained by
ture did not have much impact on tool wear of WC Rohatgi et al. [58] and Ames et al. [59], the graphite par-
tools. Coelho et al. [26] discussed the same experience ticles in Al matrix act as solid lubricant while drilling.
for WC and PCD tools. This conclusion can probably The hardness of GrA-Ni1 was also lower than
wave out the fact that abrasion is the cause of tool wear Al-9Si.20SiC and this was a favorable factor for machin-
while machining of SiC reinforced MMCs. In this work, ability. Scanning electron microscope (SEM) photo-
the authors had developed an empirical relationship graphs show the tool wear as in gure below clearly
among tool wear and milling speed. Further, Looney witnessing the worn-out carbide cutting edges while
et al. [51] examined the effects of cutting speed on tool drilling of ber and particle reinforced magnesium
wear, cutting forces, and surface nish while machining
of SiC reinforced Al matrix MMC. They concluded that
CBN tool exhibited the best performance compared
to silicon nitride tool whereas carbide tools worn out
signicantly at a rapid rate.
Drilling: In the experimental work carried out by
Coelho et al. [52, 53], they presented results of machin-
ability tests performed in conventional speed drilling
and high-speed drilling. These tests were carried out with
the PCD tool on Al-based MMC with 15% SiC
reinforcement. In this attempt, comparison was made
with results of PCD drill bits with that of HSS, diamond
coated HSS, WC, and TiN coated carbide tools. It was
concluded (as in Fig. 4) that PCD coated tools give bet-
ter performance under different cutting conditions.
Moreover, tool life was not affected signicantly by
the cutting speed. Lane [54] conrmed the same in his FIGURE 5.Research on conventional machining of MMCs for the last 10
ndings. While drilling of Al 2014 reinforced with SiC, years.
FABRICATION AND MACHINING OF METAL MATRIX COMPOSITES
FIGURE 6.Work removal rate (a), electrode wear (b), machining time (c)
in machining by dry EDM and oil EDM [95]. # Elsevier. Reproduced by
permission of Elsevier. Permission to reuse must be obtained from the
rightsholder.
alloys. A typical ank wear can be noticed in both the
cases. Microcracks and fatigue are the regular symptoms
of wear when Mg alloys reinforced with short ber
Al2O3 undergone drilling. As shown in the gure, these
short bers abrade the carbide tool.
The tool witnessed small grooves on the surface paral-
lel to the direction of cut. The carbide tool surface is
abraded by SiC due to its high hardness that results in
tool wear, which can be controlled by using PCD tools
to some extent.
Milling: Coelho et al. [26] studied the milling of SiC
reinforced Al-based MMC using carbide and PCD tools.
In this work, an empirical relationship between tool
wear and milling speed had been developed. The speed
that had little effect in turning and drilling caused faster
ank wear while milling operation. Cronjager et al. [60]
explained the formation of BUE and relevant chip
561
formation thereafter above feed rate of 0.6 mm=tooth
while milling. It was recommended to use coolant for
such high feed rate. Although chip formation occurred
at speed of 250 m=min, tool wear increased with cutting
speed. Lane [54] in his ndings suggested that HSS and
coated tools were suitable for milling of cast MMCs
from an economic point of view. Also, carbide tools
had lower tool life.
From the above survey, it is very much clear that the
volume fraction, morphology, distribution of the rein-
forced particles, and properties of the matrix are the
major factors that affect the machining of MMCs.
Grinding: Very less research work is available for
grinding of MMCs as reported by Vaccari and Lane
[61]. Zhong et al. [62] reported results obtained while
grinding of 2618=Al2O3=10p, 20 p aluminum-based
MMC reinforced by either Al2O3 or SiC with SiC and
diamond wheels both in rough and ne conditions.
Grinding at a speed between 1000 and 2000 m=min gave
a nish of 0.3 mm Ra. No subsurface damage except very
few particle cracks appeared while ne grinding of
MMC with the diamond wheel. Similar types of study
on grinding was performed by Zhong [63], wherein
2618=Al2O3=10p, 20p MMC with Al2O3 reinforcement
was micro ground by grinding wheel embedded with
small diamond grains. Hence, it can be concluded that
aluminum-based MMC can be rough grinded economi-
cally by SiC wheel followed by nish grinding with
diamond wheel.
The actual application of nished composites greatly
depends on the quality of the surface produced, for
instance, surface hardness, roughness, residual stresses,
etc. Under the effect of cutting forces, it is quite evident,
the soft matrix and the hard reinforcement do not experi-
ence uniform deformation. The outer machined surface
may have lower hardness as compared to the inner sur-
face. Work hardening and residual stresses make the outer
surface acts as Achilles Heel for composites. According
to Yanming and Bangyan [64], composites with ne par-
ticle reinforcement often face compressive stresses in the
machined surface. However, reinforcement with coarse
particles has an advantage of heat stress and elastic
stress-free machined surface. Also, composites with coarse
particle reinforcement have thicker and softer machined
surface as compared to ner particles reinforcement.
EDM OF COMPOSITES
Machining is the phenomena of removing unwanted
material from the workpiece in order to convert it into
desired shape. In traditional machining, this removal is
in the form of chips with application of force by cutting
tool. When it comes to machining hard materials like
MMCs, a severe setback is faced by the tool that results
in its failure as explored by Pramanik et al. [65]. The arena
of conventional machining has been ruled out with the
advent of new and improved techniques. These techni-
ques can prove their existence by machining hard to
machine and complex shaped materials with greater accu-
racy and better surface nish. These nonconventional
562 P. SINGH BAINS ET AL.

FIGURE 7.Developments in EDM process.

machining techniques include the electro-discharge, laser
beam, abrasive water jet, electrochemical, and electro-
chemical discharge machining. Among these, electrical
discharge machining (EDM) is one of the controlled but
violent thermal processes in which a certain volume of
metal is eroded by producing millions of electric dis-
charges in a matter of seconds. Abbas et al. [66] revealed
that although several advances have been made in this
area, yet this process aims to improve the efciency of
machining. It ensures to acquire good material removal
rate (MRR) along with lesser tool wear and improved
surface quality both at macro and micro levels. Now
becoming established, many industries producing
sophisticated products employ EDM as a nontraditional

FIGURE 8.Removal rate when EDM PRMMCs and non-reinforced aluminum alloy [102]. # Elsevier. Reproduced by permission of Elsevier. Permission
to reuse must be obtained from the rightsholder.
FABRICATION AND MACHINING OF METAL MATRIX COMPOSITES
FIGURE 9.Research on EDM of MMCs [72]. # Elsevier. Reproduced by
permission of Elsevier. Permission to reuse must be obtained from the
rightsholder.
concept of machining to produce molds and dyes, aero-
space components, automotive parts, and surgical com-
ponents as explored by Ramasawmy et al. [68]. Early
1940s have witnessed the development of this process
wherein the material had been removed by a tool passing
electric discharge into the workpiece through a dielectric
uid, according to Ho and Newman [67]. This controlled
process was designed to machine the component by
vaporizing the material from the metal surface. It is a
noncontact-type highly developed machining processes
by which material is removed from the workpiece by melt-
ing and vaporization with the help of thermal energy of
electric sparks. The voltage without touching the work-
piece generates the spark through a small gap that ows
through the dielectric and thus ionizes it. Material of
any hardness, but electrically conductive, can be
machined well using this process as per the ndings of
Ramasawmy et al. [68]. In the 1980s, EDM got even bet-
ter with the introduction of computer numeric control
(CNC) in machining that enhances its ability to a higher
FIGURE 10.Micro-gear-array machined by UEDM [137]. # Elsevier.
Reproduced by permission of Elsevier. Permission to reuse must be
obtained from the rightsholder.
563
FIGURE 11.Research on hybrid machining of MMCs for the last 10
years.
level. It ensures that the automated operation and control
of EDM along with tool changing was possible as
observed by Houman [69].
History of EDM
The evolution of EDM can be traced way back in
1770 when Joseph Priestly, an English scientist, was
experimenting with electricity. He found that the erosion
of metallic surface can be caused by a spark produced
between two conductors as quoted by Webzell [70].
In 1943, Lazarenko and Lazarenko [71] found that
the spark propagated in the presence of dielectric
(insulated) gave rise to a thermal energy which when
focused on a particular area, caused the erosion. After
that era, it was found that the destructive nature and
properties of the spark could be used in a constructive
way. This principle was employed in the machining of
hard to machine metals and alloys. Garg et al. [72]
explored that few years later, in 1950, use of resist-
ancecapacitance type power supply was developed by
Lazarenko and Lazarenko. It played a signicant role
in the foundation and development of the EDM tech-
nology. In the 1980s the use of electric charge for the
removal of broken taps and drills from hydraulic valves
left no stone unturned in the popularity of the EDM
process. This revolution became the basis for developing
a servo system that worked on an electronic circuit by
which a spark is generated in the gap between the tool
and workpiece without actually touching the later. In
1978, while EDM of cemented carbide found application
in micro-holes. In 1980, the EDM got even better with
the entry of computers in this eld that worked as a
facilitator in automation of the EDM. It enhanced the
efciency of EDM, in general and machining, in parti-
cular, a lot. Then in 1994, Rajurkar [73] examined
certain future trends in functioning of EDM. These
included machining of advanced materials, powder
mixing in the process to attain mirror-like nish of the
surface, use of ultrasonic vibrations, etc. In 1990s,
according to Kansal et al. [74], powder mixed EDM
was developed in which a ne powder is mixed in dielec-
tric. Later on, it came out to be a hybrid material
564
removal process. With the advent of this process, the
surface nish and machining quality of a material had
a mirror-like emergence. Further, Uno and Okada [75]
and Uno et al. [76] investigated that a material machined
with powder mixed EDM (PMEDM) exhibits high
resistance to abrasion and corrosion. Sidhu et al. [77]
noticed a considerable improvement in conductivity
and corrosive resistance of the surface while machining
of SiC reinforced Al matrix composite with PMEDM
technique. They advocated PMEDM as a suitable
machining option for MMCs in order to enhance their
surface properties. This technique (earlier known as
additive EDM) originated in the late 1970s but came
to existence in the 1990s as observed by Erden and Bilgin
[78] and Jeswani [79]. Zhixin et al. [80] in 1995 developed
a new method to cut holes in ceramics and named it as
ultrasonic vibration pulse electronic discharge machine
(UVPEDM). They acclaimed high MRR by use of this
variant in EDM. Ogawa et al. [81] revealed the similar
kind of investigation wherein they claimed to achieve
micro holes of almost double depth by UVPEDM as
compared to conventional EDM. It was an era when
EDM experienced alterations with respect to its increase
in efciency and control.
Recent Developments in EDM
Stovicek [82] revealed that EDM, from the last few
years, has made a signicant breakthrough in medical,
optical, dental, jewelry industry, etc. Ramasawmy and
Blunt [83] explored that the material of any hardness
and shape can be machined provided material should
be electrically conductive in nature. Shrivastava and
Dubey [84] and Jain [85] discussed the developments in
EDM, brought up in different areas depending upon
the trends and interest of researchers for example:
Ultrasonic vibration EDM
Dry EDM
Powder mixed EDM
EDM in water
Micro EDM
According to Guo et al. [86], the ultrasonic vibrations
when associated with EDM increased the efciency by
improving dielectric circulation. They claimed that this
technique can increase the cutting efciency by 30% and
reduce the roughness of the machined surface from 1.95
Ra to 1.7 Ra. It results in efcient debris removal between
the tool and workpiece and helped to increase the MRR.
The efforts and recommendation by Zhang et al. [87] in
their research work aimed at spark erosion by direct cur-
rent (DC) power supply instead of usual pulse power sup-
ply for spark erosion that reduced the cost and made the
equipment simpler to use. Huang et al. [88] investigated
the effects of ultrasonic vibration on EDM performance
while drilling of holes in Nitinol wherein machining
efciency increased more than 60 times, and that too
without affecting the tool wear rate (TWR). Egashira
and Masuzawa [89] laid a groundwork by developing a
new method for micro ultrasonic machining wherein
P. SINGH BAINS ET AL.
workpiece was made to vibrate instead of the tool. Using
this technique, micro-holes of diameter as small as 5 mm
were machined successfully in quartz, silicon, and glass.
Size reduction of the nished product has dragged
researchers attention to micro EDM. According to
Rajurkar and Yu [90], complex shaped micro cavities,
micro-holes, and micro shaft of diameter as small as 5
m are possible to machine with micro EDM. Several
similar attempts using micro EDM had been made by
Masuzawa et al. [9193] for producing micro parts such
as micro pins, micro nozzles, micro shafts, micro cavi-
ties. According to Zhang et al. [94], dry machining was
introduced to lessen the use of dielectric. This dielectric
causes pollution on decomposition and release harmful
gases like Co and CH4 and adds to cost to manage the
waste thereof. Yu et al. [95] investigated the machining
by dry EDM of cemented carbide material and com-
pared its characteristics with those of oil die sinking
EDM. The results conrmed that dry EDM showed
almost six time higher work removal rate and one-third
lower electrode wear as compared to EDM in presence
of dielectric medium (as in Fig. 6). The total machining
performance appears to be same as oil die sinking EDM.
Kunieda et al. [96] in their study enlisted individual
characteristics of dry EDM as under:
1. Dry EDM has negligible tool electrode wear for any
pulse duration.
2. Structure of EDM is compact due to the absence of
dielectric uid and its storage space.
3. Gap between tool and workpiece is less as compared
to conventional EDM. Hence, the force of reaction is
also lesser.
4. After melting, residual stresses are lower due to the
decrease in thickness of resolidication layer.
Evolution of powder mixed hybrid EDM proved to be a
breakthrough that signicantly affected performance
and stability of EDM. Wong et al. [97] experienced near
mirror nish in surface of the nished part by using
graphite, silicon, glass, Al, and SiC of different sizes in
dielectric. In this process, a proper combination of
powder and workpiece along with good knowledge of
fundamentals is necessary. Further, moving a step
ahead, Yan et al. [98] explored that the resistance to
corrosion and surface hardness can also be improved
by adding correct combination of powder in dielectric.
Showing the concern over environment, health and
safety and following their norms, water, as an alternate
to oil as dielectric, was used in 1981, as in research work
published by Jeswani [99]. He revealed that distilled
water as dielectric resulted in high MRR and less tool
wear as compared to kerosene. Although machining
accuracy was poor, yet surface nish was better in this
technique. Jilani and Pandey [100] compared machining
with distilled water, tap water, and tap waterdistilled
water mixture using copper tool with negative polarity.
Tap water dielectric gave best machining performance
with negligible electrode wear.
FABRICATION AND MACHINING OF METAL MATRIX COMPOSITES 565

EDM Applications in Machining of MMC
The attributes of EDM of composite material
resemble much to those of monolithic materials yet the
presence of reinforcement material makes the process
more complicated and slower. The EDM of MMCs
has been extensively accepted by the industry due to
competitive machining cost and features. Hocheng et al.
[101] investigated the material removal rate while EDM
of SiC reinforced aluminum matrix MMC. They
revealed that material removal rate is higher at the
beginning of the process and it slows down afterwards
due to the entrapment of debris in the gap between
workpiece and tool. MRR increased with an increase
in current accompanied by tapering and surface rough-
ness that can be avoided by high current and shorter
pulse-on time. The effect of current and pulse on time
are shown in Fig. 8. Muller and Monaghan [102, 103]
noticed that the MRR increases with change in current
and pulse on time to some extent and then decreases.
Similar results have been reported by Seo et al. [104]
while EDM of SiC reinforced Al matrix. They found
that material removal rate can be maximized by an
optimum combination of peak current and pulse on
time, thus the disturbed coordination among two leads
to larger tool wear. Patel et al. [105] revealed that
weight percentage and size of SiC in SiC reinforced
Al matrix composite were the prominent parameters
while machining of such MMCs using micro-EDM.
They investigated that MRR and EWR increase with
servo speed and pulse on duration, while decrease with
the increase in sparking gap voltage. Same trend had
been noticed with hole taper. Yan et al. [106] after a
detailed survey examined the various machining pro-
cesses that were performed on various MMCs. They
examined the machining of Al2O3=6061 Al MMC using
rotary EDM coupled with a disk like electrode. Similar
investigations were carried out by Mamalis et al. [107]
while machining ceramicmetal composite
plasma-sprayed WCCo coated steel plates. Muller
and Monaghan [108] compared the EDM of particle
reinforced MMC with other nonconventional machining
processes such as LBM and abrasive water jet machining.
They investigated that although EDM process is suitable
for machining of such type of materials with lesser surface
damage but MRR was very slow. Mahdavinejad and
Mahdavinejad [109], while machining the WCCo com-
posite, noticed that increase in pulse times or duration
increase the instability of EDM process and also explained
the methods to control it. In WCCo composite, the
cracks developed on the surface because of melting and
evaporation of cobalt before WC particles melting, result-
ing in unstable machining. As a result of this instability,
recast layer is formed due to melting and vaporization,
and it makes the surface of workpiece uneven and
rough. Chiang [110] emphasized that current has a direct
effect on TWR whereas pulse on time has an inverse
effect. TWR can be reduced by using rotary tube electrode
in EDM and electrode having higher electric, thermal, and
wear resistance along with easy manufacturability.
Amongst the various defects observed during EDM,
residual stress, which is generated due to irregular solidi-
cation of molten metal, is the most signicant defect. It
may lead to failure, especially under tensile loading or
may also cause corrosion [111, 112]. When the induced
residual stresses exceed the ultimate strength of the
material, the failure appears in the form of cracks [113].
Various material removal mechanisms such as melt-
ing, spalling, and chemical oxidation=decomposition
put a shadow of effect on machining of composites
depending on material composition, micro-structure,
and context of EDM. From the above review, it is
evident that sinking EDM has been graced up by most
of the reported research work, wire EDM (WEDM)
has been least tried. Although it has scaled new heights
in few areas, the research in EDM of MMCs is still in its
developing stage. Mechanism of machining processes for
most of the composite materials is still hard to under-
stand. The in-depth investigations in nonconventional
machining of MMCs may bring new revolution in their
processing. Table 3 shows a comparison of different

TABLE 3. Comparison of different nonconventional machining processes.

Heat
Tool affected MRR Surface Machine
Process Medium consumption zone (mm3=min) nish (mm) cost Efciency Advantages Drawbacks

USM Abrasive Med None 1520 2.76.8 Low High Good surface nish, conical hole, tool wear, low
in water minimum damage MRR
AJM Abrasive Low None 1.85.8 5.57.3 Med High No thermal damage, thick Roundness of cutting edge,
in gas section cutting noise level, water wastage
ECM Electrolyte Very low None 0.0970.371 3.35.9 Med Low No change in material Hazardous waste is
property, less tool wear, generated, less literatures
no recast layer available
WEDM Dielectric High Yes 7.84.5 2.15.5 Low High Cutting of curved surfaces Expensive tooling, low
oil MRR, thermal damage
EDM Dielectric High Yes 0.5-21 1.57.5 Low High Cutting of complex parts Expensive tooling, low
oil MRR, thermal damage
LBM Air Very low Yes 0.1 0.40.5 High Very high Narrow kerf, high Thermal damage, fumes
processing speed, and dust generation
exibility
566
nonconventional machining processes with EDM.
Although low MRR and high tool wear are the vulner-
able factors in the performance of EDM, yet these can
be overcome by several other advantages when
compared with other non-conventional techniques.
ABRASIVE FLOW MACHINING
The surface nish has become an important concern
in order to increase the performance and serviceability
of the nished component. In production cycle, as
described by Rhoades [114], almost 15% of total machin-
ing cost is of the nishing operations. It includes the
involvement of labor-intensive traditional methods for
nishing like lapping, honing, etc. which adds to
increase in cost and wastage of time. Moreover, these
methods are suitable for parts with simple geometries
and shapes and are found to be unsuitable for complex
geometries. This issue had been solved with the advent
of the abrasive ow machining (AFM) that was
developed by Extrude Hone Corporation in 1960s as a
method to deburr, polish, and radius hard-to-reach sur-
faces. Kalpakjian and Schmid [115] explored it to be well
suited for surface nishing of soft material like alumi-
num to hard and brittle materials like glass, ceramics,
silicon, carbides, and mold steels. In this technique, an
abrasive media is forced to ow through or across the
workpiece and nish the surfaces and edges where
restriction is caused to this media. Material is removed
from the workpiece by the action of a focused abrasive
media that comprises of abrasives and a semisolid
visco-elastic=visco-plastic carrier that ows across the
surface to be nished. Even typically unreachable areas
and a large number of parts in a single xture can be
worked upon by this technique. Jain [116] explored a
number of other similar techniques that have been
developed for surface nishing, for instance, elastic
emission machining, Magnetic abrasive nishing, mag-
netic oat polishing, magneto rheological nishing, etc.
The self-deformable abrasive media as per the geometry
of workpiece is the virtue that makes it advantageous
and more versatile to use over other processes. Accord-
ing to Benedict [117], the AFM had been successfully
employed to a variety of diverse jobs like cutting threads
into glass rods, nishing of aerofoil surfaces of impellers,
cutting titanium foil. Spring collects as quoted by Kim
and Kim [118] and diesel injector nozzles as revealed
by Jung et al. [119] also nd application of the AFM
technique. Sankar et al. [120] described that process
parameters of the AFM, for example, MRR, surface n-
ish, and surface integrity are signicantly affected by
various direct and indirect factors. These include fea-
tures of the workpiece, machine tooling, part geometry,
and nature and properties of abrasive media. An enor-
mous amount of research study has been carried out in
optimization of process parameters of the AFM. AJM
does not generate high temperatures and, as a result,
no thermally affected zone is induced therein. Besides
the advantages of the AFM, certain limitations have
also been reported by Benedict [117]. The low MRR
P. SINGH BAINS ET AL.
and low nishing rate are often difcult to avoid in this
process. The sticking of the abrasive particles into the
workpiece is also a serious issue. The cutting accuracy
is restrained by hole tapering due to inevitable aring
of abrasive jet. However, these limitations can be over-
come by employing different variants of AFM that
achieve better results. Jain [116] has reported several
applications of this process in the eld of aerospace,
medical sector, automobile parts, and in molds and dyes.
Kozak and Oczos [121] explored some of the advanced
manufacturing processes that can be hybridized with
conventional and nonconventional methods to develop
a new process having superior manufacturing and con-
trolling capabilities. They suggested some of the pro-
cesses like abrasive electrochemical machining
(AECM) and abrasive EDM (AEDM).
Optimization of process parameters of the AFM by
proper and correct knowledge can be helpful in
enhancing the efciency and productivity with minimum
cost and efforts. Hamatani and Ramulu [122] investi-
gated the machinability of high-temperature particulate
reinforced ceramic TiB2 =SiC and SiC=Al MMC by an
abrasive water jet. They concluded it to be a fair
machining method for both metal and ceramic matrix
composites for both piercing and slot cutting. The impor-
tance of the number of cycles in this regard has been
reported by Williams and Rajurkar [124] in their research
work. They concluded that workpiece faced certain
amount of abrasion during initial cycles, but afterwards
stability in MRR and surface nish was noticed. Jain
and Adsul [123] contradicted the aforesaid ndings by
reporting that MRR increases nonlinearly with increas-
ing number of process cycles. However, surface rough-
ness decreased with increase in the number of cycles as
per their study. The size and concentration of abrasive
particles play vital roles in enhancing process perfor-
mance. Jain [116] and Jain and Adsul [123] have reported
similar trends in their ndings. Jain [113] suggested the
right size of abrasive particles to be between 8 and 500
meshes (grit), and concluded that smaller the grain size
better the surface nish. Similarly, Jain and Adsul [123]
concluded that both MRR and surface roughness decline
with the increase in mesh size of abrasive particles. Wil-
liams and Rajurkar [124] found that good surface nish
can be achieved even by coarse grains of the abrasive
media. They also explored that cutting rate increases pro-
portionally with extrusion pressure and recommended
0.7 MPa to be right extrusion pressure. Further, it was
also concluded by them that increase in stiffness of abras-
ive media and extrusion pressure results in an increase in
MRR. Extrusion pressure experiences a setback due to
the internal resistance of abrasive particles while owing,
as reported by Rhoades [114]. Viscosity of the abrasive
media is a prominent factor that affects the performance
of the process. Williams and Rajurkar [124] also reported
that more viscous abrasive media improves the MRR
and surface nish of the machined product. Wang and
Weng [125] explored some cheaper and more efcient
abrasive media that can enhance the performance of
the AFM. According to them, vinyl-silicone polymer
FABRICATION AND MACHINING OF METAL MATRIX COMPOSITES
(or silicone rubber) is an alternative that has good
deformation and low ow effect without sticking to the
workpiece. They also concluded that abrasive with small
sizes can produce smoother surfaces as compared to large
abrasive sizes. It may be more time-consuming, yet the
polishing efciency is good. Sankar et al. [126] studied
the relationship between extrusion pressure and change
in surface roughness (DRa) and concluded it to be opti-
mum at about 6 MPa. Similarly, the relationship between
weight percentage of processing oil (plasticizer) and DRa
also showed an optimum at 10 wt%. They observed that
nishing and material removal mechanism for alloys were
quite different from MMCs. Increase in extrusion pressure
and number of cycles varies directly with an increase in
material removal rate, and they change inversely with
the change in oil content in the medium. Sankar et al.
[127] in their ndings also discussed that performance of
the AFM could be enhanced if rotary motion to the work-
piece made can be provided. They concluded that the
shearing force acting on the MMC workpiece is higher
in this mechanism, and consequently higher surface rough-
ness and MRR are achieved. Muller and Monaghan [128]
concluded AWJ to be appropriate for rough cut applica-
tions (feed rates up to v 450 mm=min), without any ther-
mal damage within the composite. Shanmugam et al. [129]
revealed the use of jetting machining technology over
Laser Machining of composites. According to them,
abrasive water jet cutting of materials showed very low
delamination except for graphite epoxy composites. They
also explored that the kerf angle and the surface roughness
along with waviness could be reduced by decreasing the
cutting speed without compromising with productivity.
HYBRID MACHININGLATEST MACHINING PROCESS
Based on research and review studies, it can be con-
cluded that technological results may deviate widely from
one another as a result of slight changes in the process
parameters. Although a lot of research had been carried
out (Fig. 11), yet the unconventional machining processes
have their own limitations regarding MRR, high specic
energy consumption, surface integrity, and inaccuracy in
geometry. To overcome these limitations, researchers are
concentrating now on hybrid machining processes like
pure hybrid process and assisted hybrid process.
Pure hybrid processes are those processes in which
several constituent process mechanisms (originating
from the different methods) simultaneously affect the
machining zone and contribute signicantly in the
material removal mechanism. For example, electro dis-
charge grinding (EDG), electrochemical discharge
machining (ECDM), powder mixed EDM (PEDM),
abrasive electric discharge nishing (AEDF), etc.
Assisted hybrid processes are those in which material
removal is dominated by only one process (the primary
source) and others are just assisting in the material
removal. For example, magnetic eld affected EDM,
laser-assisted turning, vibration-assisted grinding,
vibration-assisted EDM, media-assisted cutting, ultra-
sonic vibration EDM (UEDM), etc.
567
In ultrasonic vibration-assisted machining (UEDM),
vibrations of small amplitude are imparted to the
moving tool or workpiece. These vibrations are within
the ultrasonic frequency range (1825 kHz), and the
piezoelectric material within the tool holder or spindle
system generates these vibrations. As explored by
Vicario et al. [130], ultrasonic-assisted machining is
advantageous mainly due to the reduction of process
forces and extended tool life. It also permits an easier
ductile machining of brittle materials like MMCs, cer-
amics, glass, etc. The vibrations to tool or workpiece
should be applied in the appropriate direction. Schubert
et al. [131] in their ndings explained that the mean
cutting force is signicantly reduced while ultrasonic
vibration-assisted turning of aluminum or aluminum-
based MMCs along the cutting direction, as compared
to conventional machining. In the case of aluminum-
based MMCs, because of a change in depth of cut, a
higher surface roughness is mostly observed. Liang
et al. [132] concluded the similar results while the
ultrasonic-assisted grinding (UAG) of silicon, where an
axial vibration gives a better surface roughness. In [133]
Liu et al. investigated the UAG of WC. They revealed
that machining of ductile material without fracture is
possible when depth of cut is below its critical depth of
cut value and same is the case with brittle materials as
depicted by Dornfeld et al. [134]. Chen et al. [135] while
machining AlZnMg alloy by adding TiC particles into
the dielectric revealed some interesting facts. They
explored that the USM when combined with EDM
developed an alloyed layer that augmented the hardness
and wear resistance of the surface. Praneetpongrung
et al. [136] explored that the ceramic material like Si3N4
can be machined by UEDM using cylindrical copper
tungsten bar that produces two times higher MRR than
the normal EDM. Tong et al. [137] carried out
micro-UAEDM on steel plate with a tungsten electrode.
They investigated the decrease in machining time by 18
times while drilling of a blind hole of 180 mm depth at
the vibration frequency of 6 kHz and the amplitude of
3 mm. They also revealed that UAEDM is an ideal
method for micro-machining of noncircular cross section
and shapes and drilling of micro-holes with high pre-
cision. The picture of the micro-gear-array structure
produced by UEDM is shown in Fig. 10. Laser-assisted
machining (LAM) found its use in turning of hard
materials wherein the laser beam is focused directly in
front of the cutting tool and softens the material to ease
the machining.
Ding and Shin [138] revealed that residual stresses
become more tensile and result in small stress penetration
depth while machining of hardened steels and better sur-
face roughness due to increase in temperature with LAM
as compared to conventional cutting. Li et al. [139] per-
formed micro-drilling of fuel injection nozzles by hybrid
process with LBM and EDM. They found out that recast
layer and HAZs which were associated with laser drilling
had been entirely eliminated in addition to remarkable
time saving. Surface integrity improvement and uni-
formity in plastically deformed surface layer had been
568
experienced by while machining of Inconel-718 with
LAM as reported by Attia et al. [140]. Similar results
had been concluded by Lei et al. [141] wherein precision
parts of Si3N4 ceramics have been made using LAM.
Higher tool life as compared to conventional metal cut-
ting had been achieved. Mainly, the ank face of the tool
experienced wear, and the rake face came across negli-
gible crater wear. Under normal conditions, no indi-
cation of surface=subsurface cracks on machined
surfaces of workpiece was experienced for LAM. Sam-
ples showed the thickness in the ranges of 24 mm,
comparatively smaller than conventional grinding. Kuo
et al. [142] used the hybrid process of micro-EDM to fab-
ricate an Nd-YAG laser to weld 3D micro parts with
high precision. They explained that great micro precision
and high failure sensitivity that are needed in
micro-assembly of the process can be achieved that could
help in the creation of microstructure with high aspect
ratio and high joint strength. Chang et al. [143] examined
an improvement in the surface roughness as compared
to traditional planning during the machining of Al2O3
ceramics. Surface roughness has been improved and
lower burs formation has been experienced by Kaminski
and Alvelid [144] while water jet machining of alloyed
steels when jet pressure was increased. Sharman et al.
[145] while ultra high pressure turning of Inconel 718
observed similar types of effects along with a decrease
in developed tensile stresses in the near surface layer.
While cryogenic machining of Inconel 718, a thicker
compressive zone below the surface was detected. The
microstructure was ne and clear, and very less plastic
deformation was noticed on the machined surface as
explored by Pusavec et al. [146].
CONCLUSIONS AND FUTURE SCOPE
MMCs are the material exhibiting properties that are
hard to be obtained from a single material otherwise.
These can be tailored and used as per the demands of
various industrial applications by suitable fusion of their
constituent materials. Aluminum is preferred as matrix
component due to its ductility and low density. PM is
one of the most promising and versatile routes for the
fabrication of composites as compared to other manu-
facturing methods. This method ensures more homo-
geneous microstructure of the fabricated MMC as
compared to other techniques. However, the existence
of a new phase in addition to impurities in the form of
carbon could be witnesses in XRD results due to partial
reaction between matrix and reinforcement. Al2O3,
reinforcement of the brittle nature, reduces the impact
strength and increases the hardness of composite while
fabrication with melt stirring technique. The interface
between matrix and reinforcement in an MMC has an
effect on the amount of martensitic transformation.
The toughness of composite deteriorates with weak
interface, but no effect on the wear resistance and hard-
ness were noticed. In situ technique as compared to ex
situ technique is considered to be more advantageous
while synthesis of MMC.
P. SINGH BAINS ET AL.
Fabrication Fabrication of MMCs determines the cor-
relation between properties and cost of the material for a
given set of constituents. Compatibility between matrix
and reinforcement is a signicant necessity for fabri-
cation. Moreover, not each combination can be easily
processed into useful composites [17]. However, some
research investigations [147] suggest that tailoring the
metal matrix interfaces is possible in order to cope with
compatibility. Economical fabrication techniques, less
costly materials, and judicial surface modication meth-
ods should be given attention as research and develop-
ment priorities. Some industrial experts advocate
optimization and evaluation of processes like the PM
technique, spray method, and modied casting techni-
ques while others suggest metal inltration and diffusion
bonding may be considered for fabrication of MMCs.
Precise hybrid manifestation in the fabrication process
can bring about a big change in efciency. For instance,
according to Ullbrand et al. [148], spark plasma sinter-
ing proved to be a promising method in PM technique
as it showed a good dispersion of the copper nanober
into the Cu matrix. Also, it can be carried out at much
lower temperature (550650 C) as compared to conven-
tional sintering (750975 C) resulting in lower densities
Conventional machining Although it is a big challenge
to machine MMC with conventional processes, it is poss-
ible to do so and an ample amount of research literature
is available related to it (Fig. 5). Proper tooling design
and controlled and automated operating conditions
make it possible. Machining of MMC, which constitutes
7090% of most MMCs is broadly affected by matrix
and fraction of reinforcement used during synthesis com-
posite. The hardness and strength of MMC affects tool
life as harder workpiece proved to be a setback to the
tool life. PCD tools and diamond coated tools emerge
out as an alternative to being relied upon for machining
(drilling, turning, and milling). CBN tool is a promising
alternative to carbide tools after PCD. Most often, PCD
tools are used for nishing operations while carbide tools
are preferred for rough machining that is economical.
Diamond coating improves the tool life, but the same
is not true for TiN coating of carbide tools. While
machining of MMCs with carbide tools, subsurface zone
experiences deterioration as a result of plastic defor-
mation of reinforcement that leads to the change of
properties of nished part. Here again, PCD tools were
best suited for cutting without much damage with clean
cut. Water-based cutting uids, although reduce the
BUEs, yet it is unable to improve the tool life.
Nonconventional Machining
EDM: Improvements being brought by EDM in the
machining process in past few years have made it most
popular among various machining processes. The
unmatched contribution of EDM to industries remains
crucial. The EDM and W-EDM in MMCs are widely
reported in the literature as indicated by the literature
review and Fig. 9. In EDM of carbon ber reinforced
composites, excellent surface characteristics, high quality,
FABRICATION AND MACHINING OF METAL MATRIX COMPOSITES
and cost-effective holes in composites on both the top and
the bottom surfaces can be achieved by smaller pulse
energy conditions. Pulse current and pulse on time are
the two factors that affect the MRR while machining of
MMC fabricated by stir casting technique. The increase
in pulse energy can result in an increase in surface rough-
ness and more massive recast layer is formed due to the
rise in temperature. High speed, small depth of cut, and
low feed rate are suggested parameters in order to achieve
better surface nish. TWR and MRR are found to be
higher for larger current and pulse on time but at the
expense of dimensional stability. A negligible work has
been carried out regarding nonelectrical parameters, for
instance, rotation of workpiece and electrode. A promis-
ing research avenue is still open in this direction. Deep
industrial oriented research as well as hybrid manifesta-
tions should be made into these parameters.
Abrasive Flow Machining: Deburring, polish, and
radius of difcult-to-reach surfaces can be handled pre-
cisely by the AFM technique. None of thermally affected
zone is induced in the workpiece due to the absence of
high-temperature buildup. Unavoidability of low MRR
and nishing rate in addition to embedding of abrasive
particles to workpiece often adds to disadvantages of this
technique. Optimization of this technique by proper and
knowledge can be helpful in enhancing the efciency
and productivity with minimum cost and efforts. Hybrid
manifestations including application of magnetic force,
orbital force, and combination with ultrasonic methods
can be a creditable approach that will add to credibility
of the AFM. Some affordable and environmentally sus-
tainable alternative media need further research and
development to make this technique more competitive.
Hybrid EDM: Powder mixed EDM improves surface
nish, material removal, and tool life in addition to
improvement in performance and stability of the pro-
cess. Use of water as a substitute of oil as a dielectric
has been introduced as a concern over environment,
health, and safety while machining. It resulted in high
MRR and lower tool wear as compared to kerosene as
dielectric. For high micro precision machining and
micro-machining of noncircular shapes and drilling of
micro-holes with high accuracy, the ultrasonic vibration
method is suitable while dry machining is very much
cost-effective. While in laser beam machining, excessive
heating tends to melts and evaporates the matrix
material as well as reinforced particles. Fiber pullout
and fracturing are the results of plastic deformation of
matrix material in ber reinforced composite. Further,
chips in the form of ductile tearing can be found when
the cutting speed is increased while machining. As a
result, some chemical reactions occur that change the
material composition while machining. Surface integrity
improvement and uniformity in plastically deformed
surface layer have been observed in these techniques.
In abrasive jet machining, the surface nish of the
machined surface relies mainly on the relative size of
reinforced and abrasive particles. Inaccuracy and linear
machining limitations are the main problem in abrasive
jet machining. There are still vast areas to be explored in
569
terms of recast layer and other geometrical aspects in
various hybrid EDM processes.
ACKNOWLEDGMENT
The authors would like to express special thanks
to IKG Punjab Technical University, Kapurthala for
supporting this research work.
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