This work investigates the hot pressing technique, to produce Al-metal matrix composites (AL-MMC) reinforced with stainless steel fibers. The effect of hot pressing parameters, temperature, holding time, and pressure, was studied from microstructural point of view. Moreover microchemical analysis was carried out for the interdiffusion zone to predict the intermetallic compounds formed through it.Finally, the mechanical properties of the composites and the fracture mechanisms under continuous/incremental monotonic loading were studied. The results revealed that the Al-MMC samples that were prepared at T=640 °C, t=0.25 hr, and P=65 MPa gave an optimum thin continuous and uniform interdiffusion zone and hence the optimum mechanical properties. This interdiffusion zone consists of different distinct phase layers of different intermetallic compounds. Failure analysis proved that damage is initiated early after loading at outer plies and propagates through inner plies until catastrophic failure occurs. The governing damage failure modes are matrix cracking, fiber debonding, and delamination.

An optimum composite technology by diffusion bonding was developed to obtain aluminum-laminated composites. Pure aluminum and duralumin laminates that have distinct properties were bonded together without the use of an intermediate binding layers or using pure Cu or Brass as intermediate layers by applying the hot pressing technique. The effect of hot pressing parameters (P,T & t) were studied from the microstructural point of view. Also, the micro chemical analysis was carried out to follow the evolution of diffusion of the different elements in the interdiffusion zone under different parameters to predict the phases that may be formed through it. The mechanical properties of the produced laminated composites, before and after age hardening, were studied. The results obtained from the microstructural analysis revealed that, binding of both laminates without using a binding material can be achieved at an optimum conditions of P=54MPa, T=500°C & t=5hrs. Excessive diffusion of copper atoms from the duralumin laminate towards the pure aluminum was recorded and attained an average depth of 135pm. This bleeding of copper atoms leads to a substantial decrease of the mechanical properties of the duralumin side. On the contrary the application of an age hardening cycle leads to an increase of hardness from 90 to 240 VHN in the duralumin laminate. To retain the level of the copper atoms in the duralumin and in the same time to secure enough diffusion that allows sufficient bonding between both laminates a copper layer of 10pm thickness was used as a binding material. Using of brass as a binding material provided a better binding effect where zinc enhances copper atoms to penetrate in the brass intermediate layer towards the pure laminate.