Recent advances in zinc-based metal matrix composites: Fabrication, properties, and future prospects

Zinc-based metal matrix composites (MMCs) represent a significant advancement in materials engineering due to their exceptional combination of mechanical, thermal, and tribological properties. Reinforced with ceramics or other materials, these composites offer superior wear resistance, strength, and stability, making them valuable for industries like automotive, aerospace, and biomedical devices. Despite their promising properties, zinc-based MMCs face challenges related to cost-effective manufacturing, optimization of reinforcement materials, and balancing mechanical performance with weight and ductility. This comprehensive review explores the current state of zinc-based composites, detailing the fabrication techniques, microstructural features, physical and mechanical properties that define their performance. Special emphasis is placed on the impact of reinforcements on hardness, tensile strength, and thermal stability, alongside challenges like porosity, grain refinement, and interface bonding. Manufacturing techniques such as stir casting, powder metallurgy, and spark plasma sintering are highlighted for their roles in shaping material performance. Furthermore, it highlights emerging applications and potential future directions, emphasizing the need for continued innovation in the development of hybrid composites and the application of advanced characterization techniques. This comprehensive analysis provides valuable guidance for optimizing zinc-based MMCs to meet specific industrial requirements and supports ongoing research into this versatile class of materials.