Microstructure and mechanical properties of novel SiC-TiC/Al-Mg-Sc-Zr composites prepared by selective laser melting

Abstract

In order to obtain high-density dual-scale ceramic particles (8.5 wt.% SiC+1.5 wt.% TiC) reinforced Al-Mg-Sc-Zr composites with uniform microstructure, 50 nm TiC and 7 µm SiC particles were pre-dispersed into 15–53 µm aluminum alloy powders by low-speed ball milling and mechanical mixing technology, respectively. Then, the effects of laser energy density, power and scanning rate on the density of the composites were investigated based on selective laser melting (SLM) technology. The effect of micron-sized SiC and nano-sized TiC particles on solidification structure, mechanical properties and fracture behaviors of the composites was revealed and analyzed in detail. Interfacial reaction and phase variations in the composites with varying reinforced particles were emphatically considered. Results showed that SiC-TiC particles could significantly improve forming quality and density of the SLMed composites, and the optimal relative density was up to 100%. In the process of laser melting, a strong chemical reaction occurs between SiC and aluminum matrix, and micron-scale acicular Al₄SiC₄ bands were formed in situ. There was no interfacial reaction between TiC particles and aluminum matrix. TiC/Al semi-coherent interface had good bonding strength. Pinning effect of TiC particles in grain boundaries could prevent the equiaxial crystals from growing and transforming into columnar crystals, resulting in grain refinement. The optimal ultimate tensile strength (UTS), yield strength (YS), elongation (EL) and elastic modulus of the SiC-TiC/Al-Mg-Sc-Zr composite were ∼394 MPa, ∼262 MPa, ∼8.2% and ∼86 GPa, respectively. The fracture behavior of the composites included ductile fracture of Al matrix and brittle cleavage fracture of Al₄SiC₄ phases. A large number of cross-distributed acicular Al₄SiC₄ bands were the main factors leading to premature failure and fracture of SiC-TiC/Al-Mg-Sc-Zr composites.

Keywords

selective laser melting / interface structure / aluminum matrix composite / mechanical properties / elastic modulus

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Central South University