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metal matrix composites: revolutionary materials for shaping the future

DISCOVER MATERIALS 2025年第1期5卷 1-45页

作者： Pooja, Km. Tarannum, Nazia Chaudhary, Pallavi Chaudhary Charan Singh Univ Dept Chem Meerut 250004 India

Research on composite materials has increasingly replaced traditional materials and alloys in an effort to create effective and lightweight solutions for a range of applications. metal matrix composites (MMCs) offer several advantages over other composites, including reduced density, improved strength-to-weight ratio, enhanced resistance to wear and abrasion, and lower thermal expansion coefficient. This review focuses on MMCs based on aluminum, copper, magnesium, titanium, and zinc including their alloys. It examines their physical and mechanical properties, fabrication techniques (e.g., liquid-phase, solid-phase, and In-situ processing), and recent advancements. MMCs have shown remarkable improvements in their properties. This makes them suitable for critical applications in aerospace, automotive, and electronics. Key findings highlight their ability to overcome the weaknesses of traditional materials by enhancing various mechanical properties. They achieve improvements in tensile strength, density, thermal expansion coefficient, elasticity modulus, toughness and fracture resistance, fatigue resistance, creep resistance, and electrical conductivity through reinforcement techniques. The article also highlights the importance of selecting suitable fabrication methods to achieve desired characteristics while minimizing costs and defects. This review serves as a comprehensive guide for researchers and industry professionals. It highlights current trends, challenges, and the significant potential of MMCs as materials for the future.

关键词： metal matrix composites Conventional materials Fabrication techniques Reinforcement

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Remelting of In Situ Fe-xTiC metal matrix composites by the Sessile Drop Method: Characteristic Temperatures and Microstructural Analysis

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STEEL RESEARCH INTERNATIONAL 2025年第5期96卷

作者： Perminov, Anton Ilatovskaia, Mariia O. Wei, Xingwen Dudczig, Steffen Fabrichnaya, Olga Volkova, Olena TU Bergakademie Freiberg Inst Iron & Steel Technol Leipziger Str 34 D-09599 Freiberg Germany TU Bergakademie Freiberg Inst Mat Sci Gustav Zeuner Str 5 D-09599 Freiberg Germany TU Bergakademie Freiberg Inst Ceram Refractories & Composite Mat Agricolastr 17 D-09599 Freiberg Germany

The remelting of Fe-xTiC metal matrix composites (MMCs) is studied using the sessile drop method. This is to determine the conditions needed for the complete dissolution of TiC precipitates in the Fe-based melt. Samples with different amounts of TiC (2, 3.5, and 5 wt%) are analyzed in a hot-stage microscope (HSM), capturing the softening and melting temperatures. A Cr-alloyed steel is selected as a matrix. Consequently, the presence of TiC elevates the melting initiation temperature above the melting point of pure iron (e.g., 1659 +/- 10 degrees C for Fe-5TiC). Furthermore, samples with higher TiC amounts exhibit higher melting initiation temperatures. This trend is confirmed by differential scanning calorimetry measurements, conducted on the representative Fe-xTiC samples. Microstructural examinations of the solidified (HSM) samples identify two distinct TiC precipitate morphologies: primary blocky/cubic and secondary eutectic plate like. For instance, the Fe-5TiC sample contains numerous blocky/cubic precipitates (7.5 +/- 3.1 mu m) clustered at the upper cross- section, while secondary plate-like precipitates (20.4 +/- 11.8 mu m) are uniformly distributed in eutectic assemblies with the matrix. This study provides meaningful insights for optimizing the production of as-cast and as-atomized Fe-TiC MMCs, particularly in selecting reinforcement levels and homogenization temperatures for complete TiC dissolution.

关键词： Fe-based Fe-TiC hot-stage microscopes metal matrix composites sessile drops TiC

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The role of tool edge geometry on material removal and surface integrity in cutting metal matrix composites

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JOURNAL OF MANUFACTURING PROCESSES 2025年 137卷 135-149页

作者： Tian, Chengjin Weng, Jian Zhuang, Kejia Xu, Dongdong Zhou, Jinming M'Saoubi, Rachid Wuhan Univ Technol Sch Mech & Elect Engn Hubei Digital Mfg Key Lab Wuhan 430070 Peoples R China Hong Kong Polytech Univ Dept Ind & Syst Engn State Key Lab Ultraprecis Machining Technol Hong Kong Peoples R China Tongji Univ Sch Mech Engn Shanghai 201804 Peoples R China Lund Univ Div Prod & Mat Engn S-22100 Lund Sweden

metal matrix composites (MMCs) possess excellent material properties due to the combination of metals and reinforcing phases, yet this reduces their machinability. Numerous studies have shown that, due to the ploughing effect of the cutting tool, the edge effect can directly impact the material removal mechanism and the generation of surface integrity. However, the influence of different cutting-edge geometries on the cutting phenomena of MMCs has not been comprehensively investigated. This study explored the effects of three cutting-edge geometries (sharp, rounded, asymmetric) on the mechanisms of material removal and surface integrity under different uncut chip thicknesses (UCT) in orthogonal cutting of Al/SiCp. The results indicated that the altered cutting edge caused by dead metal zone (DMZ) played a dominant role in the material removal mechanisms of MMC. While cutting force was primarily affected by edge geometry, it showed minimal variation. Chip morphology varied with UCT, transitioning from long and continuous chips to more fragmented chips as UCT increased. Surface and subsurface defects worsened at higher UCT, with limited differences due to edge geometries. The DMZ formation transformed the blunt edge into a relatively sharp one, eliminating the effect of edge geometries. This effect became more pronounced as UCT increased and persisted even under small UCT and sharp edge conditions. Besides eliminating the edge effect, the DMZ introduced a lateral fish-scale-like surface defect, significantly compromising post-cutting surface integrity.

关键词： metal matrix composites Cutting-edge geometries Material removal mechanisms Surface integrity

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Fabrication of AlSi10Mg-AlN metal matrix composites using laser powder bed fusion technology

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CANADIAN metalLURGICAL QUARTERLY 2025年第2期64卷 362-382页

作者： Comhaire, J. Donaldson, I. W. Bishop, D. P. Dalhousie Univ Dept Mech Engn Halifax NS Canada GKN Powder Met Auburn Hills MI USA

AlSi10Mg has evolved to become a standard aluminium alloy utilised in additive manufacturing (AM), owing to a robust response to processing and desirable properties such as a high-strength-weight ratio. Despite these promising traits, the stiffness, thermal conductivity, and thermal stability of AM AlSi10Mg remain inadequate for certain applications. In an effort to bolster performance in these areas, coupling the alloy with controlled levels of ceramic particulate is under investigation. Specifically, research on the incorporation of aluminium nitride (AlN) additions and how these influence the processability of AlSi10Mg in the context of laser powder bed fusion has been considered. Using a design of experiments (DOE) approach, the effects of AlN concentration, laser power, scan speed, and hatch spacing on final part density were studied. The optimal range of VED was determined to be 60-80 J/mm3 for all chemistries considered. However, the presence of AlN was found to reduce as-built density as the ceramic concentration increased. AlN remained largely unaffected by laser irradiation. AlSi10Mg a & eacute;volu & eacute;pour devenir un alliage d'aluminium standard utilis & eacute;dans la fabrication additive (FA), gr & acirc;ce & agrave;sa r & eacute;ponse robuste au traitement et & agrave;ses propri & eacute;t & eacute;s d & eacute;sir & eacute;es telles qu'un rapport r & eacute;sistance-poids & eacute;lev & eacute;. Malgr & eacute;ces traits prometteurs, la rigidit & eacute;, la conductivit & eacute;thermique et la stabilit & eacute;thermique d'AlSi10Mg FA restent insuffisantes pour certaines applications. Dans un effort pour am & eacute;liorer les performances dans ces domaines, le couplage de l'alliage avec des niveaux contr & ocirc;l & eacute;s de particules c & eacute;ramiques est sous investigation. Sp & eacute;cifiquement, des recherches ont prises en compte l'incorporation d'ajouts de nitrure d'aluminium (AlN) et la mani & egrave;re dont ceux-ci influencent l

关键词： Laser powder bed fusion additive manufacturing aluminium metal matrix composites

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Rate-temperature dependence of tension-compression asymmetry in metal matrix composites: Mechanism and damage-coupled constitutive modeling

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INTERNATIONAL JOURNAL OF IMPACT ENGINEERING 2025年 201卷

作者： Wang, Ruifeng Yuan, Kangbo Wang, Jianjun Liu, Lanting Chen, Longyang Zhao, Sihan Li, Boli Guo, Weiguo Northwestern Polytech Univ Sch Aeronaut Xian 710072 Shaanxi Peoples R China Northwestern Polytech Univ Sch Mech & Civil Engn & Architecture Xian 710129 Shaanxi Peoples R China Taiyuan Univ Technol Inst Appl Mech Coll Mech & Vehicle Engn Taiyuan 030024 Shanxi Peoples R China

The lack of an insight on micro-mechanisms and constitutive models for the tension-compression asymmetry (TCA) in lightweight metal matrix composites is a major impediment to accurate structural assessment and full exploitation of their application potential, and has attracted growing interest in recent research. This paper aims to report our innovative work on the mechanism investigation and constitutive modeling of the rate-temperature dependence of TCA in TiB2/2024 Al composite. Experimental results indicate that the TCA extent in both yield stress and strain hardening increases notably with both strain rate and temperature. Microscopic characterizations demonstrate that TCA is primarily attributed to the variation of damage evolution under different deformation paths. matrix damage always dominates in compression, while damage evolution under tensile loadings is more complex. As temperature increases, the dominant damage mode in tension transits from particle cracking to interface debonding. These tensile damages in high-strain-rate tests will initiate earlier and are distributed over a larger deformed area. Based on the new insights towards damage evolution mechanism, a damage-coupled viscoplastic constitutive model considering the stress state effect was established to quantify TCA over wide ranges of strain rate and temperature, which can be extended and applied to other metal matrix composites.

关键词： metal matrix composites Tension-compression asymmetry Rate-temperature coupling dependence Damage evolution Constitutive modeling

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Experimental investigation and mechanical characterization of Al 5051 with nickel/titanium powder metal matrix composites using stir casting

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MULTISCALE AND MULTIDISCIPLINARY MODELING EXPERIMENTS AND DESIGN 2025年第1期8卷 1-11页

作者： Theja, P. Charan Suresh, R. Reddy, M. Chandra Sekhara Annamalai Univ Fac Engn & Technol Dept Mech Engn Chidambaram 608002 Tamil Nadu India Sri Venkateswara Coll Engn Dept Mech Engn Tirupati 517507 Andhra Pradesh India

In the manufacturing field, there is a need for advanced materials to benefit from newly developed advanced technologies. This experimental analysis involved the fabrication of lightweight metal matrix composites made up of Aluminium 5051 and nickel and titanium powders as reinforcements via stir casting. Aluminium 5051 with nickel and titanium leads to materials that are better suited for demanding manufacturing applications, enabling innovative designs and enhanced performance. Among the various nonferrous materials, Aluminium-based materials are unique because of their corrosion resistance, specific weight and strength. This material will become more promising if it is hybridized using a variety of reinforcements. The fabricated hybrid composites were processed using ASTMstandards and subsequently mechanically characterized. This mechanical characterization involved evaluating the tensile strength, yield strength, compression strength and hardness of samples prepared with different weight percentages of reinforcements, namely Al5051 + Ni(5%) + Ti(2%), Al5051 + Ni(10%) + Ti(3%) and Al 5051 + Ni(15%) + Ti(4%). Comparative studies were also performed with pure Al5051 upon mechanical characterization of the samples. The tensile strength increases with an increase 2.02% of reinforcement of either the nickel or titanium powder. However, the yield stress first increases and further decreases with increasing reinforcement percentage of the nickel and titanium nano powders. Compared with those of pure Al5051, all three mechanical properties, strength, yield stress and compression strength, increased to their feasible maxima.

关键词： Al 5051 Hybridization Reinforcements Nickel and titanium nano powders Stir casting metal matrix composites Mechanical characterization

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Effect and mechanism of powder morphology on mechanical properties of nickel-based metal matrix composites TiC-IN738LC in laser powder bed fusion

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PROGRESS IN ADDITIVE MANUFACTURING 2025年 1-19页

作者： Shu, Chang Chen, Siyuan Lei, Peiran Shu, Xuedao Abdel-Wahab, Adel Essa, Khamis Univ Birmingham Birmingham England Ningbo Univ Ningbo Peoples R China Zhejiang Key Lab Part Rolling Forming Technol Ningbo Peoples R China Univ Birmingham Dubai Dubai U Arab Emirates

The fabrication of high-performance nickel-based metal matrix composites through laser powder bed fusion (L-PBF) represents a dominant area of research. This study introduces Titanium Carbide (TiC) nanoparticles and prepares the TiC-IN738LC composites using mechanical and wet chemical mixing methods. The morphology and sphericity of the powders produced by these methods were analyzed and observed that powders processed chemically retained superior morphology and characteristics over ball-milled, such as enhanced sphericity and uniform nanoparticle distribution. The mechanical properties of both methods were examined, revealing that powder morphology significantly influences the mechanical performance. Tensile tests indicated that TiC-IN738LC composites prepared chemically exhibited a ductility of 3.26%, a 55% improvement over the ball-milled method, although their strength of 1416 MPa was marginally lower than the 1518 MPa achieved through ball-milled. Additionally, microstructural defects are mitigated by wet chemically mixing route. A high-fidelity Computational Fluid Dynamics (CFD) modeling was employed to investigate the effects of powder sphericity on melt pool dynamics, elucidating the mechanisms behind lack of fusion and verifying the influence of powder physical characteristics on the microstructure and mechanical properties. This study clarifies the role of powder morphology in determining the mechanical properties of nickel-based metal composites in L-PBF processes.

关键词： metal matrix composites Laser-powder bed fusion Powder preparation Defect formation mechanism

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Investigations of nonequal molar CrMoNbTaTiZr RHEA in metal matrix composites with alumina

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MATERIALS CHEMISTRY AND PHYSICS 2025年 333卷

作者： Chen, Kuan-Yi Huang, Hao-Hsuan Wei, Tzu-Hsiang Huang, Zhi-Wei Wang, Woei-Ren Chen, Chi-San Yeh, Jien-Wei Tsai, Che-Wei Natl Tsing Hua Univ Dept Mat Sci & Engn Hsinchu Taiwan Natl Tsing Hua Univ High Entropy Mat Ctr Hsinchu 30013 Taiwan Ind Technol Res Inst Taiwan Hsinchu Taiwan

A lightweight nonequal molar CrMoNbTaTiZr refractory high entropy alloys (RHEAs) were studied in the present work. As Ti is added to nonequal molar CrMoNbTaTiZr alloy, the crystal structure of the alloys consists of BCC and C15 Laves phase. However, the single BCC structure is obtained through the annealing process. The microstructure and compression performance of the alloys has been discussed in different Ti contents. The alloys possess a theoretical density of about 7.44 g/cm3 and high yielding strength of up to 630 MPa at 900 degrees C. Furthermore, the alloy powders have been refined by high-energy ball milling with Al2O3 particles. Then, the RHEA matrix composites were successfully synthesized after the sintering at 1700 degrees C. These composites have shown high relative density and excellent wettability. The thermal properties of RHEA composites have also been analyzed and discussed through heat capacity, thermal conductivity, and thermal expansion analysis from ambient temperature to 1400 degrees C.

关键词： Refractory high entropy alloys Powder metallurgy metal matrix composites Thermal analysis

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A novel online sensing approach for monitoring micro-defect and damage mode during the plastic deformation of metal matrix composites: Experiment and crystal plasticity analysis

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JOURNAL OF MATERIALS PROCESSING TECHNOLOGY 2025年 338卷

作者： Tang, Xuefeng He, Chuanyue Wang, Xinyun Hu, Feifei Deng, Lei Xie, Jianxin Fu, M. W. Huazhong Univ Sci & Technol Sch Mat Sci & Engn State Key Lab Mat Proc & Die & Mould Technol Wuhan 430074 Peoples R China Univ Sci & Technol Beijing Beijing Adv Innovat Ctr Mat Genome Engn Beijing 100083 Peoples R China Univ Sci & Technol Beijing Key Lab Adv Mat Proc MOE Beijing 100083 Peoples R China Hong Kong Polytech Univ Res Inst Adv Mfg Dept Mech Engn Hong Kong Peoples R China

Online monitoring of defect evolution during metal forming is crucial for achieving closed-loop control of product quality. The incorporation of reinforcement phases in metal matrix composites (MMCs) results in changes to micro-defect evolution and damage modes, thereby rendering the online monitoring of defect evolution more complex and challenging. Here, the authors proposed a novel intelligent sensing approach that can not only detect the formation of micro-defect but also identify the damage mode during plastic deformation of MMCs. By leveraging anomaly detection with an autoencoder to analyze the power spectral density (PSD) of acoustic emission (AE) signals collected during plastic deformation, the signals from the TC4 matrix and TiB reinforcement in a discontinuously reinforced titanium matrix composite (DRTMC) can be distinguished. Based on the intelligent sensing framework, it was found for the first time that the evolution of the TiB signals PSD correlates with defect evolution, and TiB fractures occur during the early to mid-stages of plastic deformation. It further utilizes autoencoders in conjunction with unsupervised clustering to associate the AE signals from TiB with two distinct damage modes: fracture of TiB whiskers and microcrack penetrating the matrix. The effects of stress state on the formation of defect and damage mode were also recognized by the developed approach. The effects of TiB content and stress state on the grain-level deformation behavior and damage evolution mechanism during plastic deformation of DRTMC were analyzed by full-field crystal plasticity simulation with uncoupled damage model. A TiB content of 3 % in TiB/TC4 enhances matrix slip and improves plastic deformation capability. However, under shear deformation, TiB's load-bearing contribution is minimal. High stress triaxiality from a notch causes TiB-induced cracks to penetrate the matrix at lower strains, leading to failure. This study provides a promising method for the on

关键词： Intelligent defect detection Acoustic emission Autoencoder Unsupervised clustering Damage mode metal matrix composites

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Additive manufacturing of metal matrix composites

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MATERIALS & DESIGN 2025年 252卷

作者： Nartu, Mohan Sai Kiran Kumar Yadav Agrawal, Priyanshi Pacific Northwest Natl Lab Nucl Sci Div Richland WA 99354 USA Idaho Natl Lab Nucl Sci & Technol Div Idaho Falls ID 83410 USA

Although metal matrix composites (MMCs) are superior to most sought-after metallic alloys, their challenging fabricability has limited their widespread use in bulk-form applications. Among the many advanced fabrication techniques, Additive Manufacturing (AM), owing to its unique capabilities to produce near-net shapes, has drawn significant traction in the past two decades, especially for materials that are difficult to process using traditional methods. However, unlike pure metal/alloy systems, MMCs are highly sensitive to the processing conditions prevailing in AM techniques due to factors such as the high melting point of reinforcement particles and the potential for in-situ reactions. Therefore, it may be a while before metal matrix composites are commercially produced via AM. This review will discuss the current state-of-the-art design, fabricability, and performance of various additively manufactured metal matrix composites (AMMCs). A particular focus will be on microstructural evolution and microstructure-property relationships. The most employed AM techniques, such as directed energy deposition, powder bed fusion, binder jetting, sheet lamination, and solid-state friction stir processing, are fundamentally different in terms of thermo-kinetics, forming the perspective for this review. A detailed comparison of microstructural evolution and process parameter optimization, including feedstock preparation methods and the role of machine learning and modeling among the different AM processes, is also presented. Finally, a critical evaluation of emerging AM technologies for MMCs is also provided, highlighting their potential advantages and challenges.

关键词： Microstructural evolution In-situ reinforcements Properties metal matrix composites Sustainability Additive manufacturing

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