Abstract: Metal matrix composite parts are manufactured by arranging matrix alloy foils and reinforcement fibers to form a bundle of matrix alloy foils and reinforcement fibers, surrounding a periphery of the bundle with metal stripping, and applying electrical current into the bundle and surrounding metal stripping while applying controlled pressure, e.g., in a press. As the bundle of matrix alloy foils and reinforcement fiber is being consolidated, the metal stripping can melt at a lower temperature than the matrix alloy foils and/or react with air to remove at least one of oxygen and nitrogen from the bundle of matrix alloy foils and reinforcement fibers. The metal matrix composite material can be consolidated in an ambient environment outside of a vacuum chamber or furnace.

Abstract: A method and associated preform for forming a structural assembly that defines a complex contour are provided. The preform and, hence, the structural assembly includes first and second skin members and a cellular core member between the first and second skin members. The skin members and/or the core member can be formed to a shape that corresponds to the desired contour of the structural member before the preform is assembled, e.g., by superplastic forming. That is, the first skin member can be disposed against a contour surface of a die to restrain the preform to the contour defined by the surface. A pressurized fluid is provided against the second skin member to urge the preform against the contour surface. A pressurized fluid is also injected in the first chamber to support the cellular core member. The preform is heated to a bonding temperature before or after being disposed against the contour surface so that the core and skin members are bonded to form the structural assembly.