Background
Aluminium-based metal matrix composites (MMCs) are attracting increasing interest across the automotive, aerospace and industrial sectors due to the growing demand for lightweight, high-performance materials. However, conventional ceramic-reinforced aluminium composites face challenges associated with particle–matrix bonding, ductility, fracture toughness and fatigue performance, which can limit their suitability for demanding structural applications. Preliminary research conducted in collaboration with an industry partner has identified promising characteristics in an alternative particulate reinforcement material. These characteristics present an opportunity to investigate novel approaches to improving interfacial bonding and mechanical performance in aluminium-based composites. The project will explore the relationship between reinforcement particle characteristics, interfacial behaviour and composite performance, with particular emphasis on the potential benefits of tailored reinforcement architectures. Cold spray processing offers a promising manufacturing pathway due to its relatively low processing temperatures and ability to produce particle-reinforced metallic structures while limiting thermal degradation of the constituent materials.
