Advancements in the fabrication of metal matrix composites: a detailed review of manufacturing and characterization techniques

Metal matrix composites (MMCs) have gained considerable attention in the aerospace sector due to their advantageous mechanical properties. This review provides a comprehensive summary of research focused on MMC manufacturing techniques, emphasizing scalability and minimizing interstitial defects. One of the main aims of this review is to highlight the importance of creating a correlation between the fabrication procedure and the methods used for their characterization. Various reinforcement combinations with distinct matrix bases are analyzed, highlighting the benefits of these combinations in an accessible manner. Among the manufacturing methods, casting stands out for its versatility, uniform reinforcement distribution, and scalability. Detailed discussion includes current casting methods, with a particular focus on stir casting, which introduces reinforcement into the molten matrix for uniform solidification, thereby reducing defect formation from inhomogeneous distribution. Additionally, a bibliographic analysis reveals other prominent methods, such as powder metallurgy, which offers efficient material use and near-net shape products, and squeeze casting, known for reducing defects and enhancing mechanical strength. The review also addresses the prospects and challenges of MMC production and their cutting-edge applications in various fields. The potential aspects currently limiting the implementation growth of metal matrix composites along with viable future research areas are also discussed in this paper.