New manufacturing process for thermally sprayed prepregs with local UD fiber reinforcement for semi solid forming of light metal MMC

Thermal spraying and thixoforging technologies can be combined in a new manufacturing method for the production of light metal matrix composites. This paper describes the production of unidirectional (UD) and tailored local fiber reinforced MMC based on this new method. For manufacturing of UD fiber reinforced metals, fiber prepregs are produced by coating of fiber bundles with light metal matrix material. For further processing to the final MMC, these prepregs are laminated, heated up and densified by thixoforging to near net-shape components. Compared to conventional technologies for the integration of fibers in light metal matrices, like squeeze casting, hot pressing and diffusion bonding, this method offers the possibility to realize complex component geometries with short cycle times. However, the focus of this paper lies on the flexible processing of fiber prepregs with local, already near net-shape fiber reinforcement by continuous fiber deposition and simultaneous coating with the matrix alloy by thermal spraying. As a case study, the manufacturing of a wheel rim with local reinforcement in the central area will be discussed.