State of the Art in Additive Manufacturing of Metal Matrix Composite for Use in Performance-Specific Application

Metal matrix composites (MMCs) have proved themselves a reliable alternative to different metals and their alloys due to their high strength-to-weight ratio, high durability; high wear corrosion resistance, high hardness and other mechanical properties. In the conventional approach, different methods like liquid-state processing (stir casting, squeeze casting etc.), solid-state processing (consolidation, physical vapour deposition or PVD, powder bending etc.), and in-situ processing are being used to manufacture metal matrix composites (MMCs). Injection molding and other in-situ processing are highly dependent upon particle size and morphology. Particle agglomeration is a common problem for liquid and solid-state processing. Again, these inhomogeneous second-phase particles influence crack initiation and propagation, thermal mismatches, residual stresses, and dislocation, making the subtracting or machining process challenging to perform. By observing these issues with the conventional approach, additive manufacturing can be considered an alternative technique to fabricating metal matrix composite. It is reported that 3D printing cannot only sort out the matrix/reinforcement bonding issues observed during conventional manufacturing processes but is also capable of providing a uniform distribution of reinforcement inside the metal matrix. Additive manufacturing allows the fabrication of functionally graded composites with any geometrical complexity, higher accuracy, and minimum production lead time. However, challenges like lack of fusion, rapid cooling, poor surface morphology and texture restrict the additive manufacturing processes to manufacturing a sound product. The current chapter summarises the recent development in manufacturing metal matrix composites (MMCs) using different additive manufacturing processes.

Keywords: Additive manufacturing (AM), Challenges, Conventional manufacturing process, Metal matrix composite (MMC), Mechanical properties, Microstructural properties, Reinforcement.