Metal matrix composites (MMCs) can be synthesized by aligning metal co
ated ceramic fibers in a shaped container and applying pressure at ele
vated temperatures. The high stresses created at the contacts between
neighboring fibers cause inelastic matrix flow that fills interfiber v
oids, reduces interfiber separations and results in composite densific
ation. The rate of densification depends on the contact's resistance t
o flow. Current contact mechanics models are unable to adequately pred
ict this resistance because they do not account for tile effect of the
(elastic) fiber. Closed-form solutions for contact stress-displacemen
t rate and contact area-strain relationships are used to describe meta
l coated fiber blunting as a function of fiber volume fraction, matrix
material non-linearity (i.e. creep stress exponent) and fiber packing
geometry. The solutions contain two unknown coefficients (c and F) wh
ich are evaluated using the finite element method. A simple model for
the consolidation of coated SiC fibers is developed in terms of the co
efficients, c and F. The model indicates that materials with a low cre
ep stress exponent are more difficult to densify as the fiber volume f
raction increases whereas, perfectly plastic materials exhibit a relat
ively weak dependence on the fiber volume fraction. (C) 1997 Acta Meta
llurgica Inc.