Abstract
This paper reports on the semi-solid processing (thixoforming) of spray-formed Al Si metal matrix composites (MMCs). In these novel MMCs, silicon—in quantities of up to 45 vol.%—was the reinforcing phase, rather than a ceramic. The project investigated all steps in the processing of the materials; mechanical tests on the products were carried out and demonstrator components were manufactured. It was shown that cylindrical billets of the MMCs could be formed in one step into intricate shapes at temperatures well below the liquidus. This confirmed that thixoforming is a safe, clean and practical method for the near net shape forming of components from materials that could be shaped only with difficulty by other techniques. The thixoformed MMCs exhibited very high specific stiffness, low thermal expansion, high specific strengths and high wear resistance.
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