Abstract Scope |
Aluminum metal matrix composites (MMCs) are highly desirable materials for precision aerospace applications, where stiffness and low mass are critical, but they are rarely used because of their cost and machining difficulty. In these applications, components typically have complex geometries and are produced in small numbers. Therefore, processing metal matrix composites additively would be the ideal solution, but MMCs with high ceramic content are not commercially available for AM. Here, using purely mechanical methods and readily available constituent powders, we fabricate composite feedstock powders optimized for laser powder bed fusion in a cost-effective, scalable manner. We demonstrate that these powders can be laser consolidated to nearly 100% relative density, providing a potential pathway for the broader adoption of these high-performance yet underused materials. |