Metal/metal composites represent a particular class of materials showing innovative mechanical and electrical properties. Conventionally, such materials are produced by severely plastically deforming two ductile phases via rolling or extruding, swaging, and wire drawing. This study presents the feasibility of producing metal/metal composites via a capacitive discharge-assisted sintering process named electro-sinter-forging. Two different metal/metal composites with CP-Ti/AlSi10Mg ratios (20/80 and 80/20 %vol) are evaluated, and the effects of the starting compositions on the microstructural and compositional properties of the materials are presented. Bi-phasic metal/metal composites constituted by isolated α-Ti and AlSi10Mg domains with a microhardness of 113 ± 13 HV_0.025 for the Ti20-AlSi and 244 ± 35 HV_0.025 for the Ti80-AlSi are produced. The effect of the applied current is crucial to obtain high theoretical density, but too high currents may result in Ti dissolution in the Ti80-AlSi composite. Massive phase transformations due to the formation of AlTiSi based intermetallic compounds are observed through thermal analysis and confirmed by morphological and compositional observation. Finally, a possible explanation for the mechanisms regulating densification is proposed accounting for current and pressure synergistic effects.

In this study one of the most innovative sintering techniques up to date was evaluated: Electro-Sinter-Forging (ESF). Despite it has been proved to be effective in densifying several different metallic materials and composites, bearing steels such as 100Cr6 have never been processed so far. Pre-alloyed Astaloy CrM powders have been ad-mixed with either graphite or graphene and then processed by ESF to produce a 100Cr6 equivalent composition. Porosity has been evaluated by optical microscopy and compared to that one of 100Cr6 commercial samples. Mechanical properties such as hardness and transverse rupture strength were tested on samples produced by employing different process parameters and then submitted to different treatments (machining, heat treatment). The experimental characterization highlighted that porosity is the factor mostly affecting mechanical resistance of the samples, correlating linearly to the transverse rupture strength. Hardness on the other side does not correlate to the mechanical resistance because process related cracking has a higher effect on the final properties. Promising results were obtained that give room to the sinterability by ESF of materials difficult to sinter by conventional press and sinter techniques.