20 June 2024 | Liang-Yu Chen, Peng Qin, Lina Zhang and Lai-Chang Zhang
Additive manufacturing (AM) of metal matrix composites (MMCs) has gained significant attention due to its potential to produce components with improved mechanical properties, reduced porosity, and complex geometries. This review summarizes recent advancements in AM technologies for fabricating MMCs, including available AM techniques, feedstock preparation, reinforcement types, and the strengthening mechanisms of MMCs. Compared to conventionally manufactured MMCs, AM-produced MMCs exhibit more uniform reinforcement distribution and refined microstructures, resulting in comparable or better mechanical properties. AM technologies also enable the fabrication of bulk MMCs with low porosity and complex geometries, such as lattice structures. Various AM technologies, including powder bed fusion (PBF), direct energy deposition (DED), binder jetting (BJ), and spraying, have been used to produce MMCs. PBF is particularly suitable for parts with complex geometries, while DED offers higher production rates. BJ is cost-effective but results in higher porosity. Spraying technologies are efficient for coating production but may result in porosity and lamellar boundaries. The feedstock for AM of MMCs typically includes powders, wires, and sheets, with powders being the most common. The choice of feedstock and reinforcement type significantly influences the properties of MMCs. Reinforcements can be pre-mixed with the metal matrix or added during the AM process. In-situ reactions can be used to form reinforcements, which can enhance the properties of MMCs. The strengthening mechanisms of MMCs include Hall–Petch, dislocation, load transfer, and Orowan strengthening. Despite the advantages of AM, challenges remain, such as the need for new methods to investigate AM-produced MMCs and the intrinsic nature of MMCs coupled with AM technologies. The review concludes that AM of MMCs offers promising opportunities for fabricating advanced composite materials with improved properties.Additive manufacturing (AM) of metal matrix composites (MMCs) has gained significant attention due to its potential to produce components with improved mechanical properties, reduced porosity, and complex geometries. This review summarizes recent advancements in AM technologies for fabricating MMCs, including available AM techniques, feedstock preparation, reinforcement types, and the strengthening mechanisms of MMCs. Compared to conventionally manufactured MMCs, AM-produced MMCs exhibit more uniform reinforcement distribution and refined microstructures, resulting in comparable or better mechanical properties. AM technologies also enable the fabrication of bulk MMCs with low porosity and complex geometries, such as lattice structures. Various AM technologies, including powder bed fusion (PBF), direct energy deposition (DED), binder jetting (BJ), and spraying, have been used to produce MMCs. PBF is particularly suitable for parts with complex geometries, while DED offers higher production rates. BJ is cost-effective but results in higher porosity. Spraying technologies are efficient for coating production but may result in porosity and lamellar boundaries. The feedstock for AM of MMCs typically includes powders, wires, and sheets, with powders being the most common. The choice of feedstock and reinforcement type significantly influences the properties of MMCs. Reinforcements can be pre-mixed with the metal matrix or added during the AM process. In-situ reactions can be used to form reinforcements, which can enhance the properties of MMCs. The strengthening mechanisms of MMCs include Hall–Petch, dislocation, load transfer, and Orowan strengthening. Despite the advantages of AM, challenges remain, such as the need for new methods to investigate AM-produced MMCs and the intrinsic nature of MMCs coupled with AM technologies. The review concludes that AM of MMCs offers promising opportunities for fabricating advanced composite materials with improved properties.