Metal Matrix Composite - Manufacturing and Forming Methods

Manufacturing and Forming Methods

MMC manufacturing can be broken into three types: solid, liquid, and vapor.

Solid state methods

• Powder blending and consolidation (powder metallurgy): Powdered metal and discontinuous reinforcement are mixed and then bonded through a process of compaction, degassing, and thermo-mechanical treatment (possibly via hot isostatic pressing (HIP) or extrusion).
• Foil diffusion bonding: Layers of metal foil are sandwiched with long fibers, and then pressed through to form a matrix.

Liquid state methods

• Electroplating / Electroforming: A solution containing metal ions loaded with reinforcing particles is co-deposited forming a composite material.
• Stir casting: Discontinuous reinforcement is stirred into molten metal, which is allowed to solidify.
• Squeeze casting: Molten metal is injected into a form with fibers preplaced inside it.
• Spray deposition: Molten metal is sprayed onto a continuous fiber substrate.
• Reactive processing: A chemical reaction occurs, with one of the reactants forming the matrix and the other the reinforcement.

Vapor deposition

• Physical vapor deposition: The fiber is passed through a thick cloud of vaporized metal, coating it.

In situ fabrication technique

• Controlled unidirectional solidification of a eutectic alloy can result in a two-phase microstructure with one of the phases, present in lamellar or fiber form, distributed in the matrix.