A Review on Metal Matrix Composites: Synthesis and Processing

Abstract

Metal matrix composites are high-technology materials that combine the ductility and toughness of metals with the high strength, wear resistance, and thermal stability of ceramic or carbon-based reinforcements. They are used extensively in the aerospace, automotive, defence, electronics, and biomedical industries and have the benefit of being able to provide lightweight design solutions in high-performance applications. This review will look into the classification, the materials that make up the matrix, and the effect of the choice of matrix and reinforcement on the behaviour of composites. It examines the important synthesis and processing routes, such as solid-state processes, such as powder metallurgy, liquid-state processes, such as stir casting and melt infiltration, and newer processes, such as compocasting and additive manufacturing. These are considered in terms of their efficiency, cost-effectiveness, microstructural control, and scalability. Long-standing issues such as porosity, inhomogeneous reinforcement distribution, and poor interfacial bonding are highly scrutinized. Recent advances, including ultrasonic-assisted casting, nano-reinforcements, interfacial engineering, and manufacturing practices inspired by Industry 4.0, are also pointed out in the review. The future opportunities focus on hybrid and functionally graded composites, sustainable processing, and AI-based optimization. This article will guide the production of the next generation of metal matrix composites to address the emerging needs of high-performance engineering processes by connecting materials science and emerging technologies.