Abstract Scope |
The mechanical and thermal properties of particle-reinforced metal matrix composites (MMCs) are attractive for high-performance defense and space applications, but fabrication of MMC components with conventional methods is difficult, costly, and typically limited to components with simple geometry. Additively manufacturing particulate MMCs with laser powder bed fusion (LPBF) would be an ideal method, but the laser consolidation of these materials has been largely unsuccessful in matching the properties of conventionally-produced MMCs. The challenges include spreading the heterogeneous powder, distributing small ceramic particles, and forming a strong bond between the metal and the ceramic. Here, by mechanically alloying AlSi10Mg powder and ceramic microparticles, we manufacture highly-reinforced aluminum composite powders with morphology tuned for AM process conditions. Using LPBF, we achieve dense consolidation of these powders at ceramic contents of over 30% and demonstrate tensile properties matching the properties of aluminum matrix composites made by conventional methods. |