Additive manufacturing of aluminum metal matrix composites: Mechanical alloying of composite powders and single track consolidation with laser powder bed fusion

Parsons, Ethan M.; Shaik, Saba Z.

doi:10.1016/j.addma.2021.102450

Cited by 27 publications

(14 citation statements)

References 57 publications

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“…In a variety of industries, metal matrix composites play an important role due to their light weight, greater durability, and outstanding resistance to wear as well as corrosion [1]. Lightweight aluminum matrix composites (AMCs) are employed in several technical applications because they have tensile strength, less coefficient of thermal expansion [2], increased mechanical and anticorrosion qualities, and a less coefficient of thermal extension [3,4].…”

Section: Introductionmentioning

confidence: 99%

Optimization and Mechanical Characteristics of AA6061/Zirconia Nanocomposites Fabricated by Ultrasonic‐Aided Stir Casting Method

Gacem

Refat

Ali

et al. 2022

Journal of Nanomaterials

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Using the Taguchi Grey response surface approach, this study investigates the effect of novel ultrasonic-aided stir casting conditions on the production of AA6061/zirconia nanocomposites. A Taguchi L16 orthogonal array was utilized to conduct the researches, which included ultrasonic power (1.75-2.5 kW), time (5-20 min), temperature (750-900°C), which can cause premature solidification, stir pressure (100-250 MPa), and reinforcement weight percentage (wt% of reinforcement). Ultrasonic-aided stir casting technique has five adjustable parameters (2-5). The ultimate tensile strength, elongation percentage, hardness, and size of the grain material were some of the metrics used to evaluate the process performance. It was decided to employ the response surface approach to model and optimize the numerous replies into one grey relational analysis. AA6061/zirconia nanocomposites were studied using statistical methods such as 3D surface plots and variance analysis. 2.2537 kW, 16.28 min ultrasonic duration, weight % of reinforcement of 1.9, stirring temperature of 700.73°C, and stirring pressure of 142.63 MPa were found to be the best parameter values.

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Section: Introductionmentioning

confidence: 99%

Optimization and Mechanical Characteristics of AA6061/Zirconia Nanocomposites Fabricated by Ultrasonic‐Aided Stir Casting Method

Gacem

Refat

Ali

et al. 2022

Journal of Nanomaterials

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“…Mechanical alloying (MA) is a high-energy ball-milling technique for the production of alloys’ metallic composites, especially capable of processing alloys from immiscible systems. , The formation mechanisms of MA are divided into three categories according to the mechanical features of the materials: ductile-ductile, ductile-brittle, and brittle-brittle . The Fe–Cu system falls into the ductile-brittle component category.…”

Section: Introductionmentioning

confidence: 99%

Highly Dispersed Cu Produced by Mechanical Stress-Activated Redox Reaction to Establish Galvanic Corrosion in Fe Implant

Zeng

Yang

et al. 2022

ACS Biomater. Sci. Eng.

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Fe has immense potential for biodegradable orthopedic applications, but it degrades slowly in the physiological environment. Inducing galvanic couple by alloying Cu to Fe using ball milling is a promising approach. However, the ductile nature of Cu leads to the cold welding of a large amount of Cu powder during ball milling, which makes it difficult to disperse uniformly in the Fe matrix. Here, a Fe−CuO implant with highly dispersed Cu particles in the matrix was developed by shift-speed ball milling and selective laser melting. Specifically, copper oxide (CuO) particles were selected as precursors and dispersed in Fe powders by ball milling since they were brittle and would not be cold-welded during ball milling. After further milling in higher energy, it was found that CuO particles reacted with Fe and generated Cu particles through a stress-activated redox reaction. Subsequently, the obtained powders were prepared into a Fe−CuO implant using selective laser melting. Microstructure examination revealed that the Cu phases in the implant were dispersed evenly in the Fe matrix, which was considered to establish a large number of galvanic couples and aggravated the galvanic corrosion tendency. Electrochemical tests indicated that the implant had improved performance in degradation behavior in terms of high corrosion current density (22.4 μA/cm 2 ), low corrosion resistance (1319 Ω cm 2 ), and good degradation stability. In addition, it presented antibacterial effects against Escherichia coli and Staphylococcus aureus by diffusion mechanisms with killing rates of 90.7 and 96.7%, respectively, as well as good cytocompatibility.

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“…Intermixing TiC particles with aluminum alloy during the WAAM resulted in grain refining and improved mechanical characteristics of the composites obtained [34,35]. Applicability of inoculating particles of oxides, carbides, metallic for improving the microstructure and mechanical characteristics of alloys was discussed in a number of review articles as follows: [36][37][38][39].…”

Section: Introductionmentioning

confidence: 99%

Microstructural Evolution of AA5154 Layers Intermixed with Mo Powder during Electron Beam Wire-Feed Additive Manufacturing (EBAM)

Zykova

Чумаевский

Vorontsov

et al. 2022

Metals

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AA5154 aluminum alloy wall was built using EBAM where the wall’s top layers were alloyed by depositing and then remelting a Mo powder-bed with simultaneous transfer of aluminum alloy from the AA5154 wire. The powder-beds with different concentrations of Mo such as 0.3, 0.6, 0.9 and 1.2 g/layer were used to obtain composite AA5154/Mo samples. All samples were characterized by inhomogeneous structures composed of as-deposited AA5154 matrix with coarse unreacted Mo articles and intermetallic compounds (IMC) such as Al12Mo, Al5Mo, Al8Mo3, Al18Mg3Mo2 which formed in the vicinity of these Mo particles. The IMC content increased with the Mo powder-bed concentrations. The AA5154 matrix grains away from the Mo particles contained Al-Fe grain boundary precipitates. Mo-rich regions in the 0.3, 0.6, 0.9 and 1.2 g/layer Mo samples had maximum microhardness at the level of 2300, 2600, 11,500 and 9000 GPa, respectively. Sliding pin-on-steel disk test showed that wear of A5154/Mo composite reduced as compared to that of as-deposited AA5154 due to composite structure, higher microhardness as a well as tribooxidation of Al/Mo IMCs and generation of mechanically mixed layers containing low shear strength Mo8O23 and Al2(MoO4)3 oxides.

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Additive manufacturing of aluminum metal matrix composites: Mechanical alloying of composite powders and single track consolidation with laser powder bed fusion

Cited by 27 publications

References 57 publications

Optimization and Mechanical Characteristics of AA6061/Zirconia Nanocomposites Fabricated by Ultrasonic‐Aided Stir Casting Method

Optimization and Mechanical Characteristics of AA6061/Zirconia Nanocomposites Fabricated by Ultrasonic‐Aided Stir Casting Method

Highly Dispersed Cu Produced by Mechanical Stress-Activated Redox Reaction to Establish Galvanic Corrosion in Fe Implant

Microstructural Evolution of AA5154 Layers Intermixed with Mo Powder during Electron Beam Wire-Feed Additive Manufacturing (EBAM)

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