Optimized Arc Wire Sprayed Fiber Prepregs for Advanced Manufacturing of Metal Matrix Composites (MMC)

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.