Among the numerous methods of producing discontinuously reinforced metal-matrix composites, technologies allowing insitu production of the reinforcing phase offer significant advantages from a technical and economic standpoint. The in-situ formation of a ceramic second phase provides greater control of the size and level of reinforcement, yielding better tailorability of the composite properties. As an example, significantly finer ceramic particulates are possible, which minimizes toughness degradation that is traditionally associated with composites containing relatively large particles. Several emerging, innovative technologies in this area are under development. As with any new technology there are technical challenges, but it is believed that these processes have unique capabilities and, thus, they present cost-effective production processes for metalmatrix composites.
In the intensive materials development activities for electronic paclazging and thermal management applications, the subclass of materials in which SiC particles reinforce aluminum alloy matrices has emerged as one with an especially attractive combination of physical properties, manufacturing flexibility, and cost. One benefit of these materials is the ability to tailor the physical properties through the selection of both reinforcement and alloy variables to match the thermal expansion coefficient of other electronic materials. In addition, the manufacturing flexibility of the various processes allows for shape complexity as well as selective reinforcement placement in the component to optimize system producibility. Finally, because raw materials are inherently inexpensive and low-cost production routes have been identified, aluminum composites may offer a range of cost-effective solutions to emerging problems in electronic paclazging and thermal-management applications.
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