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Aluminum-based materials produced by powder metallurgy processing offer a number of interesting and potentially high impact commercial opportunities in the automotive industry if the range of properties available can be expanded in a cost-effective manner. This paper reviews some of these new developments in materials and processes and also provides information that is helpful in assessing their readiness for near-term commercial implementation in the automotive market.

The improvements in elastic modulus, wear resistance, and control of physical properties provided by incorporating ceramic reinforcements into aluminum alloys provide new opportunities for lightweight automotive structures. In some applications, however, properties such as ductility and fatigue resistance are also important, requiring aluminum matrix composites designed specifically to meet these needs. This paper will review the characteristics of SiC particle reinforced aluminum composites produced by powder metallurgy methods, with particular emphasis on how this processing approach can provide materials with unique combinations of properties. Currently available products will be highlighted along with a review of the state of commercial readiness and costs of these materials.