Authors : Maaz Bahauddin Naveed

Volume/Issue : Volume 11 - 2026, Issue 6 - June

Google Scholar : https://tinyurl.com/ycy9ra45

Scribd : https://tinyurl.com/d5pdk3b9

DOI : https://doi.org/10.38124/ijisrt/26jun2045

Note : A published paper may take 4-5 working days from the publication date to appear in PlumX Metrics, Semantic Scholar, and ResearchGate.

Abstract : : Metal matrix composites (MMCs) are widely used in a variety of advanced industrial fields because of their high modulus and strength, in addition to other desirable properties at high temperatures, such as wear resistance and corrosion properties. These properties encourage the material to be used in a variety of applications. MMCs possess these qualities, which is why this is the case. For the past few decades, the method of additive manufacturing (AM) has been the focus of interest as one of the prospective technologies that can be applied to construct MMCs. This attention has been directed toward the manufacturing approach. The field of additive manufacturing (AM) for metal-metal composites (MMCs) is the subject of this article, which examines the current advancements and activities that have taken place in this field. The various additive manufacturing (AM) technologies that are currently available, the various types of reinforcement, the preparation of feedstock, the fundamentals of synthesis in the AM process, typical AM-produced MMCs, the strengthening mechanisms of MMCs, the challenges that are required to fabricate MMCs, and potential interests in the field are all highlighted in this article. The AM method of manufacturing MMCs displayed mechanical properties that were equivalent to or even superior to those of the conventionally manufactured ones. This was proved when compared to the MMCs that were created using the regular MMC production procedure. This occurred as a result of the reinforcement being distributed uniformly throughout the material and the tiny microstructure. In addition, the technology of additive manufacturing can be applied to construct MMC lattice structures and geometrically complex components of MMC items. Additionally, it can be utilized to generate bulk MMCs with a substantially lower porosity. According to what was stated earlier, it has been noted that a significant number of AM-fabricated MMCs have been made. These MMCs include titanium matrix composites, aluminum matrix composites, nickel matrix composites, and iron matrix composites, amongst others. Both the technology and the parameters of additive manufacturing (AM) are highly dependent on the types and contents of reinforcements that are chosen. This, in turn, has an impact on the qualities of the MMCs that are produced by AM. Orowan strengthening, load transfer strengthening, dislocation strengthening, and Hall–Petch strengthening are all examples of different sorts of strengthening processes that have been identified in such MMCs. These four separate pathways have been identified as strengthening mechanisms. There are, however, a number of drawbacks that exist between the AM technologies and the regular manufacturing techniques, and these drawbacks can be solved for the properties of MMCs. Nevertheless, there are a lot of opportunities for improvement. Despite this, there are still more challenges to overcome: concerns about AMproduced MMCs, including their intrinsic properties in connection with AM technologies, new methods and tools for studying them, and AM process problems. Only these are some of the issues being addressed at this critical time. Thus, the paper finishes by examining AM of MMCs' difficulties and future interests. This concludes the paper. This article mentions additive manufacturing, feedstock, metal matrix composites, microstructure, and performance.

References :

1. Mortensen A and Llorca J 2010 Metal matrix composites Annu. Rev. Mater. Res. 40 243–70
2. Yang H Y, Yan Y F, Liu T S, Dong B X, Chen L Y, Shu S L, Qiu F, Jiang Q C and Zhang L C 2021 Unprecedented enhancement in strength-plasticity synergy of (TiC+Al₆MoTi+Mo)/Al cermet by multiple length-scale microstructure stimulated synergistic deformation Compos. B 225 109265
3. Lei J B, Shi C, Zhou S F, Gu Z J and Zhang L C 2018 Enhanced corrosion and wear resistance properties of carbon fiber reinforced Ni-based composite coating by laser cladding Surf. Coat. Technol. 334 274–85
4. Dong Z L, Peng Y F, Zhang X H and Xiong D B 2021 Plasma assisted milling treatment for improving mechanical and electrical properties of in-situ grown graphene/copper composites Compos. Commun. 24 100619
5. Yong H, Wei X, Hu J F, Yuan Z M, Guo S H, Zhao D L and Zhang Y H 2021 Hydrogen storage behavior of Mg-based alloy catalyzed by carbon-cobalt composites J. Magnes. Alloys 9 1977–88
6. Tang S Y, Ummethala R, Suryanarayana C, Eckert J, Prashanth K G and Wang Z 2021 Additive manufacturing of aluminum-based metal matrix composites—a review Adv. Eng. Mater. 23 2100053
7. Kumar D, Phanden R K and Thakur L 2021 A review on environment friendly and lightweight magnesium-based metal matrix composites and alloys Mater. Today 38 359–64
8. Chen L Y, Li J X, Zhang Y, Lu W J, Zhang L C, Wang L Q and Zhang D 2016 Effect of low-temperature pre-deformation on precipitation behavior and microstructure of a Zr–Sn–Nb–Fe–Cu–O alloy during fabrication J. Nucl. Sci. Technol. 53 496–507
9. Maruyama B 1999 Discontinuously reinforced aluminum: current status and future direction JOM 51 59–61
10. Munir K S, Kingshott P and Wen C E 2015 Carbon nanotube reinforced titanium metal matrix composites prepared by powder metallurgy—a review Crit. Rev. Solid State Mater. Sci. 40 38–55
11. Yang H Y, Yue X, Wang Z, Shao Y and Shu S L 2020 Strengthening mechanism of TiC/Al composites using Al-Ti-C/CNTs with doping alloying elements (Mg, Zn and Cu) J. Mater. Res. Technol. 9 6475–87
12. Yang H Y, Cai Z J, Zhang Q, Shao Y, Dong B X, Xuan Q Q and Qiu F 2021 Comparison of the effects of Mg and Zn on the interface mismatch and compression properties of 50 vol% TiB₂/Al composites Ceram. Int. 47 22121–9
13. Saboori A, Dadkhah M, Fino P and Pavese M 2018 An overview of metal matrix nanocomposites reinforced with graphene nanoplatelets; mechanical, electrical and thermophysical properties Metals 8 423
14. Saboori A, Moheimani S K, Dadkhah M, Pavese M, Badini C and Fino P 2018 An overview of key challenges in the fabrication of metal matrix nanocomposites reinforced by graphene nanoplatelets Metals 8 172
15. Dong B X, Ma X D, Liu T S, Li Q, Yang H Y, Shu S L, Zhang B Q, Qiu F and Jiang Q C 2021 Reaction behaviors and specific exposed crystal planes manipulation mechanism of TiC nanoparticles J. Am. Ceram. Soc. 104 2820–35
16. Ezugwu E O and Wang Z M 1997 Titanium alloys and their machinability—a review J. Mater. Process. Technol. 68 262–74
17. Miracle D B 2005 Metal matrix composites—from science to technological significance Compos. Sci. Technol. 65 2526–40
18. Xie X, Ma Y, Chen C, Ji G, Verdy C, Wu H, Chen Z, Yuan S, Normand B, Yin S et al 2020 Cold spray additive manufacturing of metal matrix composites (MMCs) using a novel nano-TiB₂-reinforced 7075Al powder J. Alloys Compd. 819 152962
19. Shi J and Wang Y C 2020 Development of metal matrix composites by laser-assisted additive manufacturing technologies: a review J. Mater. Sci. 55 9883–917
20. Yu W H, Sing S L, Chua C K, Kuo C N and Tian X L 2019 Particle-reinforced metal matrix nanocomposites fabricated by selective laser melting: a state of the art review Prog. Mater. Sci. 104 330–79
21. Savolainen J and Collan M 2020 How additive manufacturing technology changes business models?—Review of literature Addit. Manuf. 32 101070
22. Balla V K, Bodhak S, Bose S and Bandyopadhyay A 2010 Porous tantalum structures for bone implants: fabrication, mechanical and in vitro biological properties Acta Biomater. 6 3349–59
23. Xu R, Chen C Q, Sun J P, He Y L, Li X, Lu M H and Chen Y F 2023 The design, manufacture and application of multistable mechanical metamaterials-a state-of-the-art review Int. J. Extrem Manuf. 5 042013
24. Cui Y W, Chen L Y, Chu Y H, Zhang L N, Li R F, Lu S, Wang L Q and Zhang L C 2023 Metastable pitting corrosion behavior and characteristics of passive film of laser powder bed fusion produced Ti–6Al–4V in NaCl solutions with different concentrations Corros. Sci. 215 111017
25. Yu L, Zhu J L, Zhang L N, Liang S X, Cheng J and Chen L Y 2023 Passivation behavior of water-quenched and heat-treated Ti–6Al–4V in Hank’s solution Adv. Eng. Mater. 25 2300754
26. Wu P, Wang J and Wang X Y 2016 A critical review of the use of 3D printing in the construction industry Autom. Constr. 68 21–31
27. Stansbury J W and Idacavage M J 2016 3D printing with polymers: challenges among expanding options and opportunities Dent. Mater. 32 54–64
28. Feng J W, Fu J Z, Yao X H and He Y 2022 Triply periodic minimal surface (TPMS) porous structures: from multi-scale design, precise additive manufacturing to multidisciplinary applications Int. J. Extrem Manuf. 4 022001
29. Li X, Peng W T, Wu W W, Xiong J and Lu Y 2023 Auxetic mechanical metamaterials: from soft to stiff Int. J. Extrem Manuf. 5 042003
30. Tan C L, Deng C, Li S, Abena A, Jamshidi P, Essa K, Wu L K, Xu G H, Attallah M M and Liu J 2022 Mechanical property and biological behaviour of additive manufactured TiNi functionally graded lattice structure Int. J. Extrem Manuf. 4 045003
31. Zhang L C and Wang J 2024 Stabilizing 3D-printed metal alloys Science 383 586–7
32. Wang J C, Liu Y J, Qin P, Liang S X, Sercombe T B and Zhang L C 2019 Selective laser melting of Ti–35Nbcomposite from elemental powder mixture: microstructure, mechanical behavior and corrosion behavior Mater. Sci. Eng. A 760 214–24
33. Hu Y B and Cong W L 2018 A review on laser deposition-additive manufacturing of ceramics and ceramic reinforced metal matrix composites Ceram. Int. 44 20599–612
34. Svetlizky D, Zheng B L, Vyatskikh A, Das M, Bose S, Bandyopadhyay A, Schoenung J M, Lavernia E J and Eliaz N 2022 Laser-based directed energy deposition (DED-LB) of advanced materials Mater. Sci. Eng. A 840 142967
35. Shamsaei N, Yadollahi A, Bian L and Thompson S M 2015 An overview of direct laser deposition for additive manufacturing; part II: mechanical behavior, process parameter optimization and control Addit. Manuf. 8 12–35
36. Dadbakhsh S, Mertens R, Hao L, Van Humbeeck J and Kruth J P 2019 Selective laser melting to manufacture “in situ” metal matrix composites: a review Adv. Eng. Mater. 21 1801244
37. Gofrey T M T, Goodwin P S and Ward-Close C M 2000 Titanium  particulate  metal  matrix composites—reinforcement, production methods, and mechanical properties Adv. Eng. Mater. 2 85–91
38. Li N, Liu W, Wang Y, Zhao Z J, Yan T Q, Zhang G H and Xiong H P 2021 Laser additive manufacturing on metal matrix composites: a review Chin. J. Mech. Eng. 34 38
39. Chen L Y, Liang S X, Liu Y J and Zhang L C 2021 Additive manufacturing of metallic lattice structures: unconstrained design, accurate fabrication, fascinated performances, and challenges Mater. Sci. Eng. R 146 100648
40. Feng Y J, Hou J B, Gao L, Cui G R and Zhang W C 2020 Research on the inhomogeneity and joint interface of in situ oriented TiBw/TA15 composites fabricated by vacuum hot-pressing sintering and canned extrusion J. Manuf. Process. 59 791–800
41. Deng Y Q, Li X F, Wu L, Yang Q F and Chen Y C 2018 Microstructure and performance of WAAM TiB₂-reinforced Al–Si-based composites Physics and Engineering of Metallic Materials: Proc. of Chinese Materials Conf. 2018 ed Y F Han (Springer) pp 321–8
42. Zhang W X, Hou W Y, Deike L and Arnold C 2022 Understanding the Rayleigh instability in humping phenomenon during laser powder bed fusion process Int. J. Extrem Manuf. 4 015201
43. Wei S S, Zhang J L, Zhang L, Zhang Y J, Song B, Wang X B, Fan J X, Liu Q and Shi Y S 2023 Laser powder bed fusion additive manufacturing of NiTi shape memory alloys: a review Int. J. Extrem Manuf. 5 032001
44. Liu Y J, Ren D C, Li S J, Wang H, Zhang L C and Sercombe T B 2020 Enhanced fatigue characteristics of a topology-optimized porous titanium structure produced by selective laser melting Addit. Manuf. 32 101060
45. Liu C X, Wang Y C, Zhang Y T, Zhang L C and Wang L Q 2024 Deformation mechanisms of additively manufactured TiNbTaZrMo refractory high-entropy alloy: the role of cellular structure Int. J. Plast. 173 103884
46. Chu Y H, Chen L Y, Qin B Y, Gao W B, Shang F M, Yang H Y, Zhang L N, Qin P and Zhang L C 2024 Unveiling the contribution of lactic acid to the passivation behavior of Ti-6Al-4V fabricated by laser powder bed fusion in Hank’s solution Acta Metall. Sin. 37 102–18
47. Zhang L C, Liu Y J, Li S J and Hao Y L 2018 Additive manufacturing of titanium alloys by electron beam melting: a review Adv. Eng. Mater. 20 1700842
48. Zhang L C and Attar H 2016 Selective laser melting of titanium alloys and titanium matrix composites for biomedical applications: a review Adv. Eng. Mater. 18 463–75
49. Yang C, Zhao Y J, Kang L M, Li D D, Zhang W W and Zhang L C 2018 High-strength silicon brass manufactured by selective laser melting Mater. Lett. 210 169–72
50. Li K M, Yang J J, Yi Y L, Liu X C, Liu Y J, Zhang L C, Zhang W C, Li W, Chen D C and Zhou S F 2023 Enhanced strength-ductility synergy and mechanisms of heterostructured Ti6Al4V-Cu alloys produced by laser powder bed fusion Acta Mater. 256 119112
51. Wang X J, Zhang L C, Fang M H and Sercombe T B 2014 The effect of atmosphere on the structure and properties of a selective laser melted Al–12Si alloy Mater. Sci. Eng. A 597 370–5
52. Hafeez N, Liu J, Wang L Q, Wei D X, Tang Y J, Lu W J and Zhang L C 2020 Superelastic response of low-modulus porous beta-type Ti-35Nb-2Ta-3Zr alloy fabricated by laser powder bed fusion Addit. Manuf. 34 101264
53. Ma H Y, Wang J C, Qin P, Liu Y J, Chen L Y, Wang L Q and Zhang L C 2024 Advances in additively manufactured titanium alloys by powder bed fusion and directed energy deposition: microstructure, defects, and mechanical behavior J. Mater. Sci. Technol. 183 32–62
54. Cui Y W, Wang L Q and Zhang L C 2024 Towards load-bearing biomedical titanium-based alloys: from essential requirements to future developments Prog. Mater. Sci. 144 101277
55. Kruth J P, Mercelis P, Van Vaerenbergh J, Froyen L and Rombouts M 2005 Binding mechanisms in selective laser sintering and selective laser melting Rapid Prototype. J. 11 26–36
56. Zhang L C and Sercombe T 2012 Selective laser melting of low-modulus biomedical Ti-24Nb-4Zr-8Sn alloy: effect of laser point distance Key Eng. Mater. 520 226–33
57. Cui Y W, Chen L Y, Qin P, Li R F, Zang Q H, Peng J H, Zhang L N, Lu S, Wang L Q and Zhang L C 2022 Metastable pitting corrosion behavior of laser powder bed fusion produced Ti-6Al-4V in Hank’s solution Corros. Sci. 203 110333
58. Qin P, Chen L Y, Liu Y J, Jia Z, Liang S X, Zhao C H, Sun H and Zhang L C 2021 Corrosion and passivation behavior of laser powder bed fusion produced Ti-6Al-4V in static/dynamic NaCl solutions with different concentrations Corros. Sci. 191 109728
59. Tian Z A, Zhang Z Y, Jiang X, Wei F, Ping S and Wu F 2023 LaSCA: a visualization analysis tool for microstructure of complex systems Metals 13 415
60. Wei C, Gu H, Gu Y C, Liu L C, Huang Y H, Cheng D X, Li Z Q and Li L 2022 Abnormal interfacial bonding mechanisms of multi-material additive-manufactured tungsten–stainless steel sandwich structure Int. J. Extrem Manuf. 4 025002
61. Sui S, Chew Y, Weng F, Tan C L, Du Z L and Bi G J 2022 Study of the intrinsic mechanisms of nickel additive for grain refinement and strength enhancement of laser aided additively manufactured Ti–6Al–4V Int. J. Extrem Manuf. 4 035102
62. Chen W, Gu D D, Yang J K, Yang Q, Chen J and Shen X F 2022 Compressive mechanical properties and shape memory effect of NiTi gradient lattice structures fabricated by laser powder bed fusion Int. J. Extrem Manuf. 4 045002
63. Chen L Y, Zhang H Y, Zheng C B, Yang H Y, Qin P, Zhao C H, Lu S, Liang S X, Chai L J and Zhang L C 2021 Corrosion behavior and characteristics of passive films of laser powder bed fusion produced Ti–6Al–4V in dynamic Hank’s solution Mater. Des. 208 109907
64. Qin P, Chen Y, Liu Y J, Zhang J X, Chen L Y, Li Y H, Zhang X H, Cao C D, Sun H Q and Zhang L C 2019 Resemblance in corrosion behavior of selective laser melted and traditional monolithic β Ti-24Nb-4Zr-8Sn alloy ACS Biomater. Sci. Eng.
65. Tang M K, Zhang L C and Zhang N 2021 Microstructural evolution, mechanical and tribological properties of TiC/Ti6Al4V composites with unique microstructure prepared by SLM Mater. Sci. Eng. A 814 141187
66. Shao C W, Li H Y, Zhu Y K, Li P, Yu H Y, Zhang Z F, Gleiter H, McDonald A and Hogan J 2023 Nano-additive manufacturing of multilevel strengthened aluminum matrix composites Int. J. Extrem Manuf. 5 015102
67. Yi J C, Zhang X W, Rao J H, Xiao J Y and Jiang Y H 2021 In-situ chemical reaction mechanism and non-equilibrium microstructural evolution of (TiB₂ + TiC)/AlSi10Mg composites prepared by SLM-CS processing J. Alloys Compd. 857 157553
68. Xiao Y M, Yang Y Q, Wang D, Zhou H X, Liu Z B, Liu L Q, Wu S B and Song C H 2024 In-situ synthesis of spatial heterostructure Ti composites by laser powder bed fusion to overcome the strength and plasticity trade-off Int. J. Mach. Tools Manuf. 196 104117
69. Huang W H and Yan J W 2023 Effect of tool geometry on ultraprecision machining of soft-brittle materials: a comprehensive review Int. J. Extrem Manuf. 5 012003
70. Feenstra D R, Banerjee R, Fraser H L, Huang A, Molotnikov A and Birbilis N 2021 Critical review of the state of the art in multi-material fabrication via directed energy deposition Curr. Opin. Solid State Mater. Sci. 25 100924
71. Singh A, Kapil S and Das M 2020 A comprehensive review of the methods and mechanisms for powder feedstock handling in directed energy deposition Addit. Manuf. 35 101388
72. Luo M J, Li R D, Zheng D, Kang J T, Wu H T, Deng S H and Niu P D 2023 Formation mechanism of inherent spatial heterogeneity of microstructure and mechanical properties of NiTi SMA prepared by laser directed energy deposition Int. J. Extrem Manuf. 5 035005
73. Lyu Z, Wang J L and Chen Y F 2023 4D printing: interdisciplinary integration of smart materials, structural design, and new functionality Int. J. Extrem Manuf. 5 032011
74. Gullipalli C, Burad P, Thawari N, Bhatt J and Gupta T V K 2022 Microstructure evolution in direct energy deposited multilayer Inconel 718 Arab. J. Sci. Eng. 47 7985–94
75. Chen L Y, Zhao Y, Meng F W, Yu T B, Ma Z L, Qu S and Sun Z Y 2022 Effect of TiC content on the microstructure and wear performance of in situ synthesized Ni-based composite coatings by laser direct energy deposition Surf. Coat. Technol. 444 128678
76. Chen K, Zeng L G, Li Z J, Chai L J, Wang Y Y, Chen L Y and Yu H 2019 Effects of laser surface alloying with Cr on microstructure and hardness of commercial purity Zr J. Alloys Compd. 784 1106–12
77. Wang G Y, Qin Y and Yang S 2022 Influence of Ni additions on the microstructure and tensile property of W-Cu composites produced by direct energy deposition J. Alloys Compd. 899 163272
78. Chai L J, Wang S Y, Wu H, Guo N, Pan H C, Chen L Y, Murty K L and Song B 2017 α → β transformation characteristics revealed by pulsed laser-induced non-equilibrium microstructures in duplex-phase Zr alloy Sci. China Technol. Sci. 60 1255–62
79. Frazier W E 2014 Metal additive manufacturing: a review J. Mater. Eng. Perform. 23 1917–28
80. Ednie L, Lancaster R J, Antonysamy A A, Zelenka F, Scarpellini A, Parimi L, Maddalena R, Barnard N C and Efthymiadis P 2022 The effects of surface finish on the fatigue performance of electron beam melted Ti–6Al–4V Mater. Sci. Eng. A 857 144050
81. Zhang P, Gao Y R, Zhang S T, Yue X J, Wang S X and Lin Z Y 2024 The mechanism of the effect of dual-sided waterjet peening on the surface integrity and fatigue performance of 12 mm thick Inconel 718 Int. J. Fatigue 178 108011
82. Sterling A J, Torries B, Shamsaei N, Thompson S M and Seely D W 2016 Fatigue behavior and failure mechanisms of direct laser deposited Ti–6Al–4V Mater. Sci. Eng. A 655 100–12
83. Keist J S, Nayir S and Palmer T A 2020 Impact of hot isostatic pressing on the mechanical and microstructural properties of additively manufactured Ti–6Al–4V fabricated using directed energy deposition Mater. Sci. Eng. A 787 139454
84. Woo W S, Kim E J, Jeong H I and Lee C M 2020 Laser-assisted machining of Ti-6Al-4V fabricated by DED additive manufacturing Int. J. Precis. Eng. Manuf. 7 559–72
85. Ostolaza M, Arrizubieta J I, Lamikiz A, Plaza S and Ortega N 2023 Latest developments to manufacture metal matrix composites and functionally graded materials through AM: a state-of-the-art review Materials 16 1746
86. Zhang C H, Li Z, Zhang J K, Tang H B and Wang H M 2023 Additive manufacturing of magnesium matrix composites: comprehensive review of recent progress and research perspectives J. Magnes. Alloys 11 425–61
87. Ziaee M and Crane N B 2019 Binder jetting: a review of process, materials, and methods Addit. Manuf. 28 781–801
88. Chen A N, Su J, Li Y J, Zhang H B, Shi Y S, Yan C Z and Lu J 2023 3D/4D printed bio-piezoelectric smart scaffolds for next-generation bone tissue engineering Int. J. Extrem Manuf. 5 032007
89. Song J Q, Lv B H, Chen W C, Ding P and He Y 2023 Advances in 3D printing scaffolds for peripheral nerve and spinal cord injury repair Int. J. Extrem Manuf. 5 032008
90. Karlsson D, Lindwall G, Lundbäck A, Amnebrink M, Boström M, Riekehr L, Schuisky M, Sahlberg M and Jansson U 2019 Binder jetting of the AlCoCrFeNi alloy Addit. Manuf. 27 72–79
91. Huang S J, Ye C S, Zhao H P and Fan Z T 2019 Additive manufacturing of thin alumina ceramic cores using binder-jetting Addit. Manuf. 29 100802
92. Holland S, Tuck C and Foster T 2018 Selective recrystallization of cellulose composite powders and microstructure creation through 3D binder jetting Carbohydr. Polym. 200 229–38
93. Zhuo L C, Liu C G, Yin E H, Zhao Z and Pang S J 2022 Low-cost and low-temperature 3D printing for refractory composite inspired by fused deposition modeling and binder jetting Compos. A 162 107147
94. Bai Y and Williams C B 2015 An exploration of binder jetting of copper Rapid Prototype. J. 21 177–85