Sintering sensitivity of aluminium metal matrix composites developed through powder metallurgy proposed technique-a review

Abstract

This paper interprets the effect of sintering parameters like sintering time and sintering temperature as well as various sintering methods on distinct properties of the material. The variation of Physical, mechanical, and Tribological behaviour depending on sintering temperature, time and method based on various aluminium metal matrix composites have been investigated. The advantages of aluminium metal matrix composites are high strength to weight ratio, high wear resistance, and erosion resistance, etc. Aluminium Metal matrix composites have vast applications in various fields like structural, automobile, and aviation industries. The optimum value of sintering parameters and choice of sintering methods has a major role in getting these required properties of aluminium metal matrix composites prepared by the powder metallurgy process.

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Sintering sensitivity of aluminium metal matrix
composites developed through powder metallurgy
proposed technique-a review
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ICAPSM 2021
Journal of Physics: Conference Series 2070 (2021) 012193
IOP Publishing
doi:10.1088/1742-6596/2070/1/012193
1
Sintering sensitivity of aluminium metal matrix composites
developed through powder metallurgy proposed technique- a
review
Anup Choudhury, Jajneswar Nanda*, Sankar Narayan Das
Department of Mechanical Engineering, S ‘O’A Deemed to be University,
Bhubaneswar, Odisha-751030, India
E-mail : *jajneswarnanda@soa.ac.in
Abstract. This paper interprets the effect of sintering parameters like sintering time and
sintering temperature as well as various sintering methods on distinct properties of the
material. The variation of Physical, mechanical, and Tribological behaviour depending on
sintering temperature, time and method based on various aluminium metal matrix composites
have been investigated. The advantages of aluminium metal matrix composites are high
strength to weight ratio, high wear resistance, and erosion resistance, etc. Aluminium Metal
matrix composites have vast applications in various fields like structural, automobile, and
aviation industries. The optimum value of sintering parameters and choice of sintering methods
has a major role in getting these required properties of aluminium metal matrix composites
prepared by the powder metallurgy process.
Key words: Sintering Time, Sintering Temperature, Sintering Methods, Aluminium Metal
Matrix Composite, Physical Properties, Mechanical Properties and Tribological Properties
1. Introduction
Conventional monolithic materials display a limitation to a decent combination of properties such as
strength, durability, density and stiffness. In order to get rid of these limitations and satisfy the ever-
increasing demand of today's technology, composites are found to be the most screaming material of
current interest. Metal Matrix Composites (MMCs) are advanced materials in which two or more
materials are fused to achieve custom-made properties. Among them Aluminium Metal Matrix
Composites (AMMCs) have substantially improved properties such as high specific strength, strong
wear resistance, and damping ability compared to base alloy properties [1]. The mechanical
characteristics of particle reinforced aluminum matrix are quite excellent (modulus, strength and creep
resistance at room and higher temperatures) owing to the inclusion of the high strength as well as high
modulus reinforcing particles such as Al2O3,TiC, SiC, TiB2 etc. and also have higher wear resistance.
Now-a-days these particulate reinforced metal matrix composites (PMMCs) are gaining priority on
account of their low cost, isotropic properties and ease of fabrication [2].
The particulate metal matrix composite (PMMCs) can be prepared by means of compacting and
sintering the properly mixed powder particles by powder metallurgy(P/M). It is one of the successfully
adopted method for MMC preparation [3,4,5,6]. The major benefit of powder metallurgy (P/M) over
other techniques is that it involves lower operating temperature and thus, avoid undesirable interfacial
reaction products among matrix and particulate reinforcement [7]. Powder metallurgy permits a great
degree of freedom in modifying the microstructure (e.g., more volume fraction as well as various size
along with morphology of the particulate reinforcement can be used) [3,4,5,8-10,6]. P/M is used for
the mass production of precise and intricate parts in low cost and sustainable manner. P/M produces
near-net-shape products and thus, eliminates the cost of machining operation. However, it leads to

ICAPSM 2021
Journal of Physics: Conference Series 2070 (2021) 012193
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various metallurgical structures along with porosity which influence the properties of P/M composites
[11]. P/M consists of various steps. Among this compaction and sintering are two major steps.
1.1. The Sintering Process
It is the method of consolidating either loose aggregate of powder or green compact of the desired
composition under controlled environments and conditions of time and temperature [41]. Sintering
process can be classified into majorly two types.
a) Solid-state sintering
b) Liquid-state sintering
1.1.1. Solid-state sintering. This is generally the process of consolidating the metal and the alloy
powders. Under this, densification of material happens mostly owing to diffusion of atoms occurring
in solid state [41].
1.1.2. Liquid-state Sintering. Densification is improved by adding a small quantity of liquid phase
(1to10 vol %). At the sintering temperature, the liquid phase predominant within the solid powders
seems to have some solubility for such solids. Between the solid particles of the compact sample, a
sufficient amount of liquid is created. The liquid phase crystallizes at the grain boundaries during
sintering, gluing the grains together. A rapid rearranging of solid particles occurs at this stage,
resulting in an increase in density. Solid-phase sintering happens later in the process, resulting in
coarse grains and a retardation of the densification rate. This is employed in the sintering of copper-tin
and tungsten-copper systems. Silicon carbide and silicon nitride, which are tough to sinter, can be
manufactured. [41].
1.2. Sintering Theory
Sintering involves the following steps.
1.2.1. Single-component System. The main material transportation mechanism is self-diffusion and the
driving force arises from a chemical potential gradient resulting from capillary forces and surface
tension occurring among particles of material [41].
1.2.2. Multi-component System. This involves more than single phase. Here there is inter-diffusion
occurring because of concentration gradient which is the main driving force for sintering along with
self-diffusion resulting from capillary forces and surface tension. Under such sintering, formation of
solid solution and liquid phase occurs along with densification [41].
1.3. Various Sintering techniques
Various commercial Sintering Techniques are conventional technique, hot press sintering, hot isostatic
pressing (HIP), spark plasma sintering (SPS) and microwave sintering. Table 1 presents the
comparison between various commercial sintering techniques.
Table 1. Comparison among various commercial Sintering Techniques
Sintering
Method
Method
description
Advantages
Disadvantages
Reference
Conventional
Sintering
Heating by
conduction,
convection
and radiation
Simple in operation.
High amount of
porosity. Coarse grains
due to grain growth
and low mechanical
performance for
[36,38]

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Journal of Physics: Conference Series 2070 (2021) 012193
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keeping through long
time duration and high
temperature.
Sintering in a
Hot Press
Electrical
resistance,
induction
heating, or
radiations
heating are
all options
for heating.
Better densification due to
application of both heat and
Pressure.
Grain coarsening due
to long sintering time
and undesirable
interfacial reactions.
High cost of mold and
equipment.
[35]
Isostatic
Pressing in a
hot
Environment
Simultaneous
heating with
consistent
pressure
applied from
all directions
Isotropic properties result from
uniform densification.
Long dwell durations
[39]
Sintering
using Spark
Plasma
Activation
through
pulsed
current,
resistance
heating, and
applied
pressure
Grain growth is inhibited,
resulting in microstructures that
are dense and fine, with good
mechanical properties.
The price is high. Mold
and sample have an
unfavorable response.
[34]
Microwave
Sintering
Volumetric
Heating
It is possible to get a fully dense
component with a tiny
microstructure. It helps you
save time and energy.
Reinforcements are distributed
evenly. The Microwave
Sintering method is less
expensive and productive than
spark plasma technique.
Complex equipment
and limitation in part
dimension.
[32-33]
2. Literature Review
2.1. Effect of Sintering Temperature and Time
2.1.1. Physical and mechanical Properties. Ghasali et al. [30] prepared Al-B4C composite through
microwave sintering of the mixture of B4C (10wt%,15wt% and 20wt%) and aluminium powders at
650°C,750°C,850°C and 9500C. It was observed that with increasing sintering temperature up to
8500C the hardness and density increases and further it decreases. Compressive strength increases up
to 750°C and further it remains constant. But bending strength remains almost constant with varying
sintering temperature.
Abdizadeh et al. [12] prepared Aluminium-zircon composite by powder metallurgy method. Sintering
is carried out at two temperatures namely 600°C and 6500C for 65 min with a temperature increase
rate of 200C/min. It is found that with increasing temperature sintered density increased for all zircon

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content. It was presented by them in Figure 1 and 2 about the variation of sintered and relative density
for Al-zircon composite with zircon content sintered at various temperatures respectively.
Figure 1. Variation of Density with zircon
content for Al-zircon composite sintered at
various temperatures.
Figure 2. Variation of Relative Density with
zircon content for Al-zircon composite sintered
at various temperatures.
Figure1 and 2 shows that with rising sintering temperature both the sintered and relative density of
samples increases. As the sintering temperature rises the atomic diffusion becomes more easier which
results in better sinterability of MMCs and density increases. Same trend of Relative Density variation
with sintering temperature was found by other researchers [17,19,21,23].
Relative density increases up to 3.5% of zircon, after which there is a decrease in the trend. This
happens because of agglomeration of reinforced zircon particles throughout sintering process. Chen et
al. [28] prepared AMMC reinforced byAl2O3and TiB2particulates synthesized using reactive sintering
of Al-B-TiO2 three-component powder mixtures. Relative density was found to increase with sintering
temperature.
Asgharzadeh et al. [26] prepared Al6061-SiC composite by powder metallurgy method following
supersolidus liquid phase sintering. Sintering was conducted at 580°C-620°C.The sintering density
and densification parameter increases from 580°C to 600°C and further it decreases. Same trend is
followed by hardness and compressive strength. Topcu et al. [27] prepared Al-B4C composite by
powder metallurgy process. Sintering of specimens are conducted at 600°C,625°C and 650°C.As the
sintering temperature increases the sintering density increases. Following results are obtained which is
shown in the table 2 below.

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Table 2. Various results obtained from Al-B4C composite
Materials
(%B4C)
Density(gm/cc)
Hardness (HV)
Impact Energy (KJ/m2)
600°C
625°C
650°C
600°C
625°C
650°C
600°C
625°C
650°C
0
2.51
2.55
2.57
38.1
36.6
25.8
80
65
42
5
2.510
2.550
2.58
40.9
39.9
45.6
59
48
38
7.5
2.42
2.540
2.55
43.8
42.9
53.5
-
-
-
10
2.40
2.520
2.54
49
52.1
56.8
58
54
52
12.5
2.37
2.510
2.52
56.1
61.1
66.6
-
-
-
15
2.36
2.500
2.51
61.5
68.1
72
26
28
24
17.5
2.35
2.500
2.55
64.8
77.2
74.8
-
-
-
20
2.35
2.500
2.53
74.1
82
82.1
12
10
9
Rahimian et al. [13] prepared Aluminium (Al)-Alumina (Al2O3) composites through powder
metallurgy method. Sintering of green compacts were conducted under inert argon atmosphere at
various temperatures namely 500°C,550°C and 600°C for time duration of 30 min,45 min,1 hour and
1.5 hour. They presented the variation of Relative Density, Yield stress, compressive strength and %
elongation with Alumina particle size for Al-Al2O3 composite sintered at various temperatures in
Figures 3,4,5 and 6 respectively.
Figure 3. Variation of Relative Density with
Alumina particle size for Al-Al2O3 composite
sintered at various temperatures.
Figure 4. Variation of Yield stress with Alumina
particle size for Al-Al2O3 composite sintered at
various temperatures.
It is presented in Figure 3 about the variation of Relative Density with Alumina particle size for Al-
Al2O3 composite sintered at different temperatures.
The Relative Density is given by,
  
  (1)

ICAPSM 2021
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From Figure 3, it was observed that relative density rises with rising sintering temperature. This can be
described by using the following equation.
  󰇡
󰇢 (2)
The diffusion coefficient, the Equation constant, the activation energy, Boltzmann's constant, and the
temperature are presented by the notation D, D0, Q, R and T respectively. So, more densification
occurs and experimental density increases at higher temperatures as diffusion increases with
temperature. This enhances the Relative Density.
Figure 5. Variation of Compressive Strength
with Alumina particle size for Al-Al2O3
composite sintered at various temperatures.
Figure 6. Variation of % Elongation with
Alumina particle size for Al-Al2O3 composite
sintered at various temperatures.
It is presented in Figure 4 and 5 about the variation of Yield stress and Compressive Strength with
Alumina particle size for Al-Al2O3 composite sintered at various temperatures respectively. Figure4
and 5 indicate that because of a stronger bonding among the particles at elevated sintering
temperatures, resulted in a higher strength. Same trend of Compressive strength variation with
sintering temperature was found by other researchers [16,17,21].
It is presented in Figure 6 about the variation of % Elongation with Alumina particle size for Al-
Al2O3 composite sintered at various temperatures. From Figure 6, the increase in elongation is due to
an increase in sintering temperature, especially close to the melting point of aluminium, because the
bonding strength among the alumina and aluminium is higher under these conditions.
Microwave assisted rapid sintering was carried out by Ghasali et al. [29] to fabricate Al-ZrB2
composite containing 1wt% cobalt (Co) and 10wt%,15wt%,20wt% ZrB2 as reinforcements at
temperatures of 600°C,700°C and 800°C.For Al-10%ZrB2-1% Co and Al-15%ZrB2-1% Co
composites, as the sintering temperature increases the compressive strength increases up to 700°C and
after that it decreases. For Al-20%ZrB2-1% Co composite it is strictly decreasing while for Al-
10%ZrB2 composite it is strictly increasing.
Wang et al. [14] prepared Al - SiC/Cu composite through powder metallurgy method. The samples
were sintered under inert argon atmosphere at various temperatures namely 650°C,700°C,750°C and
800°C for a time duration of 2h. Figure 7 presents the variation of density with sintering temperature

ICAPSM 2021
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for SiC/Cu-Al composite while Figure 8 represents the variation of Micro hardness and Strength with
sintering temperature for SiC/Cu-Al composite.
Figure 7. Variation of Density with Sintering
Temperature for SiC/Cu-Al composite.
Figure 8. Variation of Micro hardness and
Strength with Sintering Temperature for
SiC/Cu-Al composite.
It is presented in Figure 7 about a weak declining trend of density with increase in sintering
temperature. This is due to decomposition of the compound Cu2O or due to the occurrence of reaction
among Al and Cu that results in lower densification behaviour of the Al-SiC/Cu composite. It is
presented in Figure 8 about the dependence of Micro hardness and Strength on Sintering Temperature
for SiC/Cu-Al composite. Figure 8 indicates that the micro hardness of the Al-SiC/Cu composite rises
with increasing sintering temperature from 650°C to 700°C. The maximum hardness was found to be
80MPa at 700°C.This is due to the change in microstructure with sintering temperature. The relatively
uniform microstructure results in this highest hardness. In case of composite sintered at 800°C, though
there is development of non-uniform microstructure the hardness of composite increases than that of
750°C because of generation of substantial intra-granular SiC grains which is not found with sintered
at 750°C.Figure 8 indicates that strength rises with rising temperature. The strength is only 33MPa at
650°C, but rises to 140MPa at 800°C.The strength at 650°C is lowest because of weak bonding
between matrix and reinforcement. At higher temperatures strength increases because of strong
interfacial bonding. Gurbuz et al. [25] prepared Aluminium-graphene nanoplatelets composite by
powder metallurgy method. The effect of different sintering times (60,120,180,300min) and different
sintering temperatures (550°C,600°C,630°C) are investigated. The best sintering time and sintering
temperature was found to be 180 min and 630°C respectively at which hardness reaches its best value.
Same trend of Hardness variation with sintering temperature was found by other researchers [17,
18, 21, 22 and 24]. Reddy et al. [31] prepared Al-Cu-Li particles reinforced to Pure Aluminium matrix
through Microwave Sintering followed by hot extrusion. They presented the influence of
reinforcement amount and sintering temperature on UTS as presented in the table 3 below. Ultimate
tensile strength (UTS) of composites were found to be lower at higher temperatures as Al matrix
become softer at higher temperatures.

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Table 3. Ultimate Tensile Strength (UTS) of Al matrix reinforced by Al-Cu-Li with varying Sintering
Temperature
Composite
Temperature(°C)
UTS(MPa)
Al-5AlCuLi
40
127.018
Al-5AlCuLi
100
114.957
Al-5AlCuLi
200
85.7834
Al-10AlCuLi
40
151.971
Al-10AlCuLi
100
130.081
Al-10AlCuLi
200
103.929
Al-15AlCuLi
40
167.472
Al-15AlCuLi
100
141.802
Al-15AlCuLi
200
125.293
Leszczyńska-Madej et al. [37] prepared Al-SiC composite through spark plasma sintering. They
conducted sintering at 580°C and 600°C at varying SiC content of 0,10,20 and 30wt%. The value of
Brinell Hardness and bending strength for varying sintering temperature and SiC content is presented
in below table 4. The sintering temperature and decomposition of the SiC strengthening phase have
major impact on hardness. Higher value of bending strength was obtained at higher value of sintering
temperature.
Table 4. Hardness and Bending Strength of Al-SiC composite sintered at temperatures of 580°C and
600°C
SiC (wt.%)
580°C
600°C
Hardness (HB)
Bending
Strength (MPa)
Hardness (HB)
Bending Strength (MPa)
0
28
225
28
225
10
31
146
52
328
20
31
87
55
331
30
33
78
35
89
2.1.2. Tribological Properties. Rahimian et al. [15] prepared Al-Al2O3 composite by powder
metallurgy route. Green compacts were sintered at various temperatures namely 500°C,550°C and
600°C for the time periods of 30 min,45 min,1hour and 1.5 hour.
They conducted wear test and presented the effect of sliding distance on wear rate of Al-Al2O3
composite for various sintering temperature (Figure9). It is found that wear loss is lower at both higher
sintering temperatures and higher sintering times. But as the sintering time reaches to 90mins, the
specimens are over-sintered and displayed higher wear as hardness get reduced because of grain
growth occurring under these conditions. It is also found that wear loss increases with increasing
sliding distance. They also presented about the effect of sintering time on wear loss for Al-Al2O3
composite at various sintering temperatures (Figure 10). Wear tests were conducted on 10wt.%
alumina composite. Except for the composites sintered at 600°C, the all-other composites show
reduction of wear loss with increasing sintering time as there is grain refinement leading to higher
hardness and thus, wear resistance. Similar thing happens for composite sintered at 600°Cfrom 45 min
to 60min.But further as the sintering time increases from 60min to 90min, there is over-sintering
leading to grain growth. With increasing grain growth hardness decreases which leads to more wear
loss.

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Figure 9. Effect of Sliding Distance on Wear
loss of Al-Al2O3 composite sintered at various
temperatures and times.
Figure 10. Variation of Wear loss with Sintering
Time for Al-Al2O3 composite sintered at
different temperatures and times.
In some research work it is found that the composite prepared by PM route shows better wear
resistance in comparison to other methods [20,40]. Some other research work also reported that
increasing the sintering temperature by 100°C, reduces the wear rate [40].
2.2. Effect of Sintering Methods
Ghasali et al. [36] prepared Al3V-Al-VC nano composite via conventional sintering, microwave
sintering and spark plasma sintering (SPS) separately. Conventional and microwave sintering was
done at 600°C while SPS was done at 450°C. They provided a nice comparison between these
Processes as provided in the below table 5. The density increases for SPS while for the other two it
decreases as there is full densification occurring without formation of any light intermediate product
and porosity. SPS samples show best hardness and bending strength than the other two samples
because of the previously mentioned cause.
Table 5. Comparison of results obtained from SPS, Microwave and conventional sintering on Al3V-
Al-VC nano composite.
SPS
Microwave
Conventional
Properties
15wt%
VC
5wt% VC
15wt% VC
5wt% VC
15wt% VC
5wt% VC
275
243
132
110
75
103
Bending Strength
(MPa)
260
162
131
95
101
70
Hardness (HV)
2.91
2.76
2.59
2.63
2.51
2.61
Density(g/cc)

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Ghasali et al. [39] prepared Al-SiC-TiC composite using pure aluminium and AA1056 aluminium
powders by both conventional and microwave sintering methods. They Provided a detailed analysis
result as presented in the table 6 below. Relative density, bending strength and microhardness
decreases with increasing sintering temperature irrespective of material and method of sintering.
Table 6. Comparison of results obtained from Microwave and conventional sintering on Al-SiC-TiC
composite
Matrix
Material
Methods of
Sintering
Sintering
Temperature(°C)
Relative
Density (%)
Bending
Strength
(MPa)
Microhardness (HV)
AA1056
Microwave
750
96.32
340
192
AA1056
Microwave
650
94.21
252
161
AA1056
conventional
750
93.63
208
137
AA1056
conventional
650
91.89
201
121
Pure Al
Microwave
750
89.71
115
86
Pure Al
Microwave
650
89.48
81
80
Pure Al
conventional
750
77.14
58
65
Pure Al
conventional
650
82.82
51
60
Ghasali et al. [23] prepared WC-Co particle reinforced to aluminium matrix by both conventional and
microwave sintering. Their results about Relative Density and Bending Strength are depicted in the
Figures 11 and 12 below.
Figure 11. Variation of relative density with
temperature for various composition and various
Sintering Methods.
Figure 12. Variation of bending strength with
temperature for various composition and
various Sintering Methods.
From Figures it is found that Bending strength value of composites prepared by microwave sintering
firstly remains below than that of conventional at 650°C but after that increases and passes above the
conventionally prepared composites after 850°C.But in case of Relative Density the final value in case
of conventionally prepared samples is more than that prepared by microwave sintering method.

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3. Conclusion
From the above literature it was found that
1. Sintering time, sintering temperature along with sintering method has major influence on
properties of Metal Matrix Composites (MMCs).
2. Optimum value of these parameters and choice of process leads to most improved properties.
So, both under-sintering and over-sintering must be avoided.
3. Denser structure is obtained under higher sintering temperatures.
4. Higher sintering time leads to unwanted grain growth and thus, degrades the mechanical
properties excluding %Elongation.
5. As the sintering temperature rises the atomic diffusion becomes more easier which results in
better sinterability of MMCs and enhances its properties.
References
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