Iron-Based Metal Matrix Composite: A Critical Review on the Microstructural Design, Fabrication Processes, and Mechanical Properties

Iron-based metal matrix composites (IMMCs) have attracted significant research attention due to their high specific stiffness and strength, making them potentially suitable for various engineering applications. Microstructural design, including the selection of reinforcement and matrix phases, the reinforcement volume fraction, and the interface issues are essential factors determining the engineering performance of IMMCs. A variety of fabrication methods have been developed to manufacture IMMCs in recent years. This paper reviews the recent advances and development of IMMCs with particular focus on microstructure design, fabrication methods, and their engineering performance. The microstructure design issues of IMMC are firstly discussed, including the reinforcement and matrix phase selection criteria, interface geometry and characteristics, and the bonding mechanism. The fabrication methods, including liquid state, solid state, and gas-mixing processing are comprehensively reviewed and compared. The engineering performance of IMMCs in terms of elastic modulus, hardness and wear resistance, tensile and fracture behavior is reviewed. Finally, the current challenges of the IMMCs are highlighted, followed by the discussion and outlook of the future research directions of IMMCs.