M. Silber, R. Gadow, Universität Stuttgart, Stuttgart, Germany
The manufacturing of light metal matrix composites (MMC) using coated fiber prepregs processed by thixoforging offers advantages regarding cost effectiveness and component geometry over well-established technologies like spray forming or diffusion bonding. In order to obtain the required globular microstructure prior thixoforging, the reinforcement fibers are thermally sprayed with the matrix material by arc wire spraying. Damage on the sensitive fibers is avoided reducing the thermal load by optimized cooling concepts. The influence of the process parameters on the component microstructure and mechanical properties is analyzed. An innovative method for manufacturing of MMC focused on the automated coating process of reinforcement fibers is presented.
Summary: By means of the thermal spraying and thixoforging of laminated one side coated prepregs, light metal matrix composites with UD fiber reinforcement can be efficiently manufactured. The main difficulty for the obtainment of a homogeneous microstructure with high fiber volume content and fine-grained matrix microstructure lies in the infiltration of the matrix material in-between the fibers.
