Advances in the Design and Development of Lightweight Metal Matrix Composites: Processing, Properties, and Applications

Lightweight metal matrix composites (MMCs) continue to attract significant interest due to their potential to deliver high mechanical performance at reduced weight, meeting the increasing demands of aerospace, automotive and advanced manufacturing sectors. Among these systems, aluminum-, magnesium- and titanium-based MMCs stand out for their favorable strength-to-weight ratios, corrosion resistance and versatility in processing. Although numerous studies have explored individual MMC families, the literature still lacks comparative reviews that integrate quantitative mechanical data with a broad evaluation of processing, microstructural control and application-driven performance. This review addresses these gaps by providing a comprehensive and data-driven assessment of lightweight MMCs. Recent advances in reinforcement strategies, hybrid architectures and processing routes—including friction stir processing, powder metallurgy and semi-solid techniques—are systematically examined. Emerging developments in syntactic metal foams and functionally gradient MMCs are analyzed in detail, along with practical considerations such as machinability, corrosion resistance, and high-temperature performance, integrated with AI/machine learning for predictive optimization. Overall, this work provides an integrated and critical perspective on the capabilities, limitations, and design trade-offs of lightweight MMCs, positioning them as sustainable and high-performance alternatives for extreme environments. By combining qualitative insights with quantitative meta-analyses and new experimental contributions, it offers a valuable reference for researchers and engineers seeking to optimize material selection and tailor the performance of MMCs for next-generation lightweight structures, surpassing previous reviews through holistic and innovation-driven insights.