New manufacturing process for thermally sprayed prepregs with local UD fiber reinforcement for semi solid forming of light metal MMC

Abstract

Thermal spraying and thixoforging technologies can be combined in a new manufacturing method for the production of light metal matrix composites. This paper describes the production of unidirectional (UD) and tailored local fiber reinforced MMC based on this new method. For manufacturing of UD fiber reinforced metals, fiber prepregs are produced by coating of fiber bundles with light metal matrix material. For further processing to the final MMC, these prepregs are laminated, heated up and densified by thixoforging to near net-shape components. Compared to conventional technologies for the integration of fibers in light metal matrices, like squeeze casting, hot pressing and diffusion bonding, this method offers the possibility to realize complex component geometries with short cycle times. However, the focus of this paper lies on the flexible processing of fiber prepregs with local, already near net-shape fiber reinforcement by continuous fiber deposition and simultaneous coating with the matrix alloy by thermal spraying. As a case study, the manufacturing of a wheel rim with local reinforcement in the central area will be discussed.

Manufacturing of Continuous Carbon Fiber Reinforced Aluminum by Spark Plasma Sintering

“…There are different reasons for operating under the liquidus line: impeding loss of metal liquid phase during pressing; inhibition of reaction products formation at the interface; reduction of residual stresses; and shrinkage. This manufacturing route, based on semi-solid consolidation of thermally sprayed prepregs, has been previously investigated with alternative consolidation methods, as for instance hydraulic pressing [20][21][22]. The MMC samples were afterwards characterized with respect to Young's modulus by resonance frequency method (IMCE, Belgium) and with respect to flexural strength by static three-point bending tests according to the standard DIN-EN-658-3 "Advanced technical ceramics-Mechanical properties of ceramic composites at room temperature" on a universal testing machine Z100 (Zwick GmbH & Co.…”