This paper reports on the semi-solid processing (thixoforming) of spray-formed Al-Si metal matrix composites (MMCs). In these novel MMCs, silicon--in quantities of up to 45 vol./100--was the reinforcing phase, rather than a ceramic. The project investigated all steps in the processing of the materials; mechanical tests on the products were carried out and demonstrator components were manufactured. It was shown that cylindrical billets of the MMCs could be formed in one step into intricate shapes at temperatures well below the liquidus.
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