Iron-Based Metal Matrix Composite: A Critical Review on the Microstructural Design, Fabrication Processes, and Mechanical Properties

doi:10.1007/s40195-024-01758-1

Abstract

Abstract:

Iron-based metal matrix composites (IMMCs) have attracted significant research attention due to their high specific stiffness and strength, making them potentially suitable for various engineering applications. Microstructural design, including the selection of reinforcement and matrix phases, the reinforcement volume fraction, and the interface issues are essential factors determining the engineering performance of IMMCs. A variety of fabrication methods have been developed to manufacture IMMCs in recent years. This paper reviews the recent advances and development of IMMCs with particular focus on microstructure design, fabrication methods, and their engineering performance. The microstructure design issues of IMMC are firstly discussed, including the reinforcement and matrix phase selection criteria, interface geometry and characteristics, and the bonding mechanism. The fabrication methods, including liquid state, solid state, and gas-mixing processing are comprehensively reviewed and compared. The engineering performance of IMMCs in terms of elastic modulus, hardness and wear resistance, tensile and fracture behavior is reviewed. Finally, the current challenges of the IMMCs are highlighted, followed by the discussion and outlook of the future research directions of IMMCs.

Key words: Iron-based metal matrix composites, Microstructure, Fabrication methods, Mechanical properties

Sai Chen, Shuangjie Chu, Bo Mao. Iron-Based Metal Matrix Composite: A Critical Review on the Microstructural Design, Fabrication Processes, and Mechanical Properties[J]. Acta Metallurgica Sinica (English Letters), 2025, 38(1): 1-44.

Figures/Tables 37

Fig. 1 Applications, microstructural design, and typical manufacturing processes of IMMCs

Table 1 Development and application of IMMCs

Reinforcement	Targeted properties	Aimed applications	Years	Developers and references
TiB₂	High-temperature stability and hot compressive yield strength	Cutting tool	1993	Saha et al. [13]
Al₂O₃-fiber	Good conductivity and dynamic shear modulus	Coil springs	1998	Masahiro Inoue et al. [14]
2-D materials	High fatigue life and fracture toughness	The mining industry and railway switches	2014	Lin et al. [15]
ZrO₂	Excellent wear resistance	Bearing materials	2021	Parveez et al. [16]

Fig. 2 A schematic illustration showing the microstructural design of IMMCs

Table 2 Summary of the commonly used reinforcement phases of IMMCs

Type	Reinforcement	Structure or crystal structure	Density, ρ (g/cm³)	Elastic modulus, E (GPa)	Melting point (°C)	E/ρ ratio (GPa cm³/g)	References
Oxide	Al₂O₃	Trigonal	3.98	370	2063	92.96	[28]
	ZrO₂	Monoclinic	5.68	210	2715	36.97	[16]
	SiO₂	Tetrahedral	2.648	75	1716	28.32	[29]
Nitride	BN	Hexagonal	2.1	865	2973	411.9	[30]
Nitride	TiN	Cubic	5.21	251	2950	48.18	[31]
Carbide	SiC	Tetrahedron	3.21	401	2730	124.92	[32]
	B₄C	Rhombohedra	2.52	460	2450	182.54	[33]
	WC	Hexagonal	15.6	650	2870	41.67	[34]
	VC	Cubic	5.77	380	1910	65.86	[35]
	Cr₃C₂	Orthorhombic	6.68	228	1890	34.13	[36]
	TiC	Cubic	4.93	400	3067	81.14	[37]
Boride	TiB₂	Hexagonal	4.51	565	2900	125.28	[38]
Boride	ZrB₂	Hexagonal	6.085	~ 550	~ 3246	~ 90.39	[39]
Composite	Zirconia toughened alumina (ZTA)	Tetragonal	4.1-4.38	400	1980	91.32-97.56	[40]
Fibers	E-glass fiber	Weave	2.58	76	1135	29.46	[41]
	Kevlar fiber	Several repeating inter-chain	1.4	131	560	93.57	[41]
	Carbon fiber	Long, tightly interlocked chains of carbon atoms	1.75-1.93	228	3652-3697	118.13-130.29	[42]
2-D materials	Graphene	Hexagonal	2.09-2.33	1000	3652	~ 454.55	[15]
2-D materials	Carbon nanotube	Hexagonal	1.3-1.4	1000	3550	714.29-769.23	[43]

Table 3 Typical examples of IMMCs in terms of their reinforcement phases, fabrication methods, and microstructure

Fig. 3 Microstructures of a hypo-eutectic 25Cr composite and b hyper-eutectic 25Cr composite. SEM images of worn surface of composite specimens after abrasion test: c hypo-eutectic composite, d hyper-eutectic composite. e Wear rates of the alloy and composite specimens after abrasion test [60]

Fig. 4 a SEM of the morphologies of GOs in the composites, b surface microhardness of the as-received and laser processed samples, c crack pinning effect by embedded GO after bending fatigue test [15], d SEM images of the GNP at grain boundaries, e corresponding EDS analyst results, f fractured GNPs in dimples [69]

Table 4 Fabrication processes, microstructure, and mechanical properties of IMMCs with different matrixs

Fig. 5 a SEM micrograph showing the morphology and distribution of TiC-304SS, b creep curves of two steels, c optical micrographs of etched TiC-304SS, d TEM image of the interface between TiC and steel matrix, e electron diffraction pattern taken from TiC particulate [84]

Fig. 6 a SEM image of the IMMC reinforced by TiB2 particles, b, c EDX map of Ti and Fe atoms, d EBSD phase map (red: hcp, yellow: bcc); e, f EBSD orientation map of TiB2 particles and ferrite, g load-displacement curves measured by nano-indentation tests for the TiB2 particles and ferrite, h TEM image showing the interface between the matrix and reinforcement phases, the white dash lines indicate interfaces and the inserted image shows dislocation aggregates at the interface [75]

Fig. 7 a SEM image of the composite microstructure, b IPF map of composite, c engineering tensile stress-strain curves of samples with different content of WC, d SEM image of the fracture morphology of specimen reinforced with 2 wt% WC [88]

Fig. 8 a OM, b SEM, and c EDS analysis of M3 sample. EBSD analysis of M3 sample: d IPF, e phase distribution map, f IPF of martensite phase; g tensile engineering stress-strain curves of IMMCs [96]

Fig. 9 a Schematic illustration of the structure of the interface in IMMC. Contact condition of b poor wettability and c good wettability between reinforcements and matrix, d TEM images of TiB2 and Fe matrix, HR-TEM image of e a rounded interface and f an interface of Fe–TiB2 parallel to the TiB2 prismatic plane $\{ {1 }0\overline{1} 0\}$ [101]

Fig. 10 a SEM image of WC particle, matrix, and reaction layer, b TEM images showing the magnified microstructure of IMMC and the indicated region shows the nano-sized Fe2W2C precipitation, c HR-TEM image of the interface between the nanoparticle and matrix, the orientation of d Fe2W2C nanoparticle, e austenite matrix [34]

Fig. 11 a SEM micrographs of composite heat treated at 900 °C. b EPMA element cartography of Fe, Ni, O, Zn on ferrite mixed powders after treatment at 900 °C under N2. SEM micrograph c, and TEM micrograph d of Fe-SiO2-ferrite system heat treated 1 h at 900 °C under N2 [97]

Table 5 Typical in situ reaction routines and Gibbs free energy of reactions for fabricating IMMC

Reinforcement phase	Chemical composition of the matrix	Reaction equations	Gibbs free energy under 1873 K (kJ/mol)
TiB₂ [107]	Fe-6 Ti-2.2 B-0.2 Nb (in wt pct)	FeTi + 2FeB + Fe = TiB₂ + 4Fe	− 121.311
TiC [108]	Fe-3.61 C-2.5 Si-0.81 Cu-0.24 Mn-0.03 Ni-0.03 Cr-0.02 Ti-0.02 Mo-0.008 S-0.02 P (in wt pct)	Ti + C = TiC	− 157.296
NbC [76]	Fe-16.7 Cr-1.1 C-0.6 Mn-0.5 Si (in wt pct)	Nb + C = NbC	− 127.794
Al₂O₃ [46]	43.14 Fe-15.85 Fe₂O₃-19.52 Cr₂O₃-7.43 NiO-14.06 Al (in wt pct)	Fe₂O₃ + 2Al = Al₂O₃ + 2Fe	− 727.151

Table 6 Summary of the commonly used fabrication methods of IMMCs

Categories	Fabrication methods	Advantages	Disadvantages	References
Liquid state	Squeeze casting	Simple process, suitable for mass production	Inhomogeneous composite structure	[117]
	Conventional casting	Simple process, low manufacturing cost	Suitable for industrial production	[37]
	Liquid phase sintering	Better wettability between the reinforced phase and matrix	Large porosity of products, poor hardness, and wear resistance	[118]
	Infiltration casting	Low equipment requirements, small investment	Poor wettability between the reinforcement phases and matrix in the finished products	[25]
	Selective laser melting	High-quality products	High cost	[28]
Solid-state	Powder metallurgy	A large variety of available reinforcement phases and a large volume fraction of reinforcement phases	Complex production process and high cost	[119]
	Spark plasma metallurgy	Good dispersion and bonding of the reinforcement phases and matrix	Difficult to apply to the preparation of large parts, complex shape parts	[120]
	SHS (self-propagating high temperature synthesis)	The simple production process, rapid reaction, high product purity	Difficult to control the reaction, large porosity and poor denseness of the products	[121]
	Exothermic dispersion	Simple reaction process	Large porosity of the resulting composites	[122]
Gas-mixing processing	Vapor-liquid synthesis	Low cost, simple process	Inhomogeneous microstructure, high energy consumption	[123]
Gas-mixing processing	Spray deposition	Low pollution, high productivity	Large porosity, low material recovery	[124]

Fig. 12 a a schematic illustration of the pressure infiltration process for fabricating IMMCs, b distribution of ZTA particles throughout the Fe-matrix, c bonding state of ZTA/Fe, d Microstructure of the composite, e comparation of the cumulative volume loss of different materials [132]

Fig. 13 a schematic diagram of a metallic die designed for the squeeze casting process. Micrographs of b etched surfaces and c etched surfaces of the castings solidified under different applied pressures of 75 MPa, d effects of applied pressure on hardness values of the specimens [141]

Fig. 14 a schematic of LPS equipment and microstructure changes during the process [149], b microstructure of the typical micrograph of specimen with BN and 0.2%-graphene, c SEM image of sintered samples at a cooling rate of 5.4 °C /s, d tensile and yield strength of sintered steels in 0.1 °C /s cooling rates [150]

Fig. 15 Schematics of a SLM system and b SLM process. Microstructure of Gr/316L steel: c optical image and d FE-SEM image. e True stress-strain curve of samples with different Gr contents. [67]

Fig. 16 Schematic illustration of a conventional casting apparatus with stirring function and b vacuum die casting [165]. EBSD maps of 10 vol% NbC reinforced AISI 440B composite: c phase present and d IPF map reveals the martensitic laths of the matrix. e Coriolis erosion wear test results [76]

Fig. 17 a Powder metallurgy process [169]. b SEM micrographs of 21% MWCNT-Fe composite sintered at 900 °C, wet milling, black arrow showing the pores. c Distribution of the reinforcements in the Fe-matrix. d True stress-strain curves of both wet and dry milled composites sintered at 1300 °C [171]

Fig. 18 a Schematic illustration of the SPS configuration [165], b the evolution of density and hardness with temperature during SPS process, c SEM image of the microstructure of the TiC reinforced IMMC [179]

Fig. 19 a Schematic illustration of SHS processes [46], b results of Vickers hardness of composite layers and matrix. SEM images of c CS sample, d GCI sample [187]

Fig. 20 a Schematic diagram of hot compaction diffusion bonding, b SEM graphic of grain boundaries and grain size, c SEM-EDS images of bonding interface of WC-8Co-steel sintered at 1220 °C [194]

Fig. 21 a Schematic diagram of XD process [197], b DSC curves obtained at different heating rate, c SEM micrograph of the composite containing a volume fraction of 30% TiC, d the load-loss mass curves [198]

Fig. 22 a Schematic diagram of MA process, b surface profile of the TiC coatings at milling duration of 35 h, BPMR of 50:1, hard substrate, c SEM image of the composite [201]

Fig. 23 Schematic diagram of VLS process [123]

Fig. 24 a Schematic of the cold spray deposition process [124]. b Surface morphology of the coating with two phases. TEM images of Fe-based amorphous phase and TiN phase: c bright-field image, d high-resolution images [212]

Fig. 25 a SEM image of the microstructure of the IMMC showing the distribution of Ti (CN) and TiB2 particles in steel matrix, b comparison of the calculated and measured modulus of the studied HMS as affected by the volume fraction of TiB2 [5]

Fig. 26 a Overview of microstructure of the V-V8C7/Fe composite. b The distribution of hardness in the composite. c EBSD band-index micrographs of zone I. Microstructure of d zoon II, e zoon III [231]

Fig. 27 SEM micrographs of the microstructure of the a TiC and b (Ti, W) C reinforced Fe-17Mn austenitic steel matrix composite. c Volume loss, d wear rate versus sliding distance for the unreinforced steel (1 and 2), TiC-reinforced composite (3 and 4), and (Ti, W) C-reinforced composite (5 and 6) [74]

Fig. 28 a SEM, b EDS image, and c EBSD phase composition diagram of 40% WC, d friction coefficient, and e wear rates of all composites [233]

Fig. 29 a TEM image of cross section of SLMed Fe/SiC composite and the corresponding SAD patterns. b Stress-strain curves of as-fabricated Fe/SiC composite and pure Fe sample. SEM micrographs of the tensile fracture surfaces of SLMed: c Fe sample and d Fe/SiC sample [240]

Fig. 30 a Schematic of CNT-IMMCs model (iron atoms are blue and carbon atoms are red), b state of the representative volume element (RVE) at 0.09 strain, c variation of atomic configuration along the slip direction, d stress-strain curves of the CNT-IMMC and pure iron, e change of ultimate strength and Young’s modulus with different radius [248]

Fig. 31 Summary of current challenges and future directions of the research of IMMCs [112]

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