Microstructure and wear property of SiC_P/AlSi10Mg composites prepared by laser powder bed fusion

Abstract

Additive manufacturing (AM) of SiC_P/Al composites has shown significant potential for expanding the application of aluminum matrix composites (AMCs) due to their outstanding mechanical properties and wear performance. However, conventional mechanically mixed powders for AM are limited due to the possible powder agglomeration and poor fluidity. In this study, the spherical SiC_P/AlSi10Mg composite powders prepared by spray granulation were employed to fabricate SiC_P-reinforced AlSi10Mg composites using laser powder bed fusion (LPBF). The impacts of laser power on microstructure evolution and wear properties of composites were systematically investigated. The results indicated that an in-situ reaction between the aluminum matrix and SiC_P during the LpBF process, resulted in the formation of particle-like and strip-like strengthening phase Al₄SiC₄. By adjusting the laser power (from 270 W to 350 W) to change the ratio of SiC_P to Al₄SiC₄, micro-defects could be effectively limited, and wear performance could be improved. Consequently, with an optimized ratio of SiC_P to Al₄SiC₄, the composite exhibited a mixed strengthening mechanism caused by the SiC_P and Al₄SiC₄ reinforcing phases. At a laser power of 310 W, the sample exhibited minimal porosity with a microhardness value reaching 265.38HV, while maintaining relatively low average friction coefficient and wear rate. In addition, compared with other studies, the hardness obtained was superior to that of the AlSi10Mg and other reported SiC_P/AlSi10Mg composites with similar volume fractions using the mixed powders.

Keywords

SiC_P/AlSi10Mg / composite powder / laser powder bed fusion / microstructure / wear property

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