On the Role of Interfacial Reactions, Dissolution and Secondary Precipitation During the Laser Additive Manufacturing of Metal Matrix Composites: A Review

Mertens, Anne; Lecomte-Beckers, Jacqueline

doi:10.5772/63045

Cited by 13 publications

(5 citation statements)

References 98 publications

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“…Several conventional manufacturing processes already exist for incorporating reinforcements into the metallic matrices to produce a wide variety of MMCs [10,11,12,13,14]. However, it is rather challenging to fabricate geometrically complex parts using these processes.…”

Section: Introductionmentioning

confidence: 99%

Characterization of Composite Powder Feedstock from Powder Bed Fusion Additive Manufacturing Perspective

2019

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This research aims at evaluating the characteristics of the 5 wt.% B4C/Ti-6Al-4V composite powder feedstock prepared by two different categories of mechanical mixing for powder bed fusion (PBF) additive manufacturing (AM) of metal matrix composites (MMCs). Microstructural features, particle size, size distribution, sphericity, conditioned bulk density and flow behavior of the developed powders were examined. The flowability of the regularly mixed powders was significantly lower than that of the Ti-6Al-4V powder. However, the flowability of the ball-milled systems was a significant function of the milling time. The decrease in the flowability of the 2 h ball-milled powder compared to the Ti-6Al-4V powder was attributed to the mechanical interlocking and the entangling caused by the B4C particles fully decorating the Ti-6Al-4V particles. Although the flattened/irregular shape of powder particles in the 6 h milled system acted to reduce the flowability, the overall surface area reduction led to higher flowability than that for the 2 h milling case. Regardless of the mixing method, incorporation of B4C particles into the system decreased the apparent density of the Ti-6Al-4V powder. The composite powder obtained by 2 h of ball milling was suggested as the best possible condition, meeting the requirements of PBF–AM processes.

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Section: Introductionmentioning

confidence: 99%

Characterization of Composite Powder Feedstock from Powder Bed Fusion Additive Manufacturing Perspective

2019

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“…The A6061 alloy has columnar dendritic solidification and a wide solidification range, which can result in cracking during solidification. The nucleant and grain-refining action of TiC and TiB 2 for Al alloys [50][51][52] induces an equiaxed solidification, avoiding crack formation; in fact, both ceramic compounds have a lattice parameter comparable with that of the matrix and they can induce an equiaxed grain growth; -…”

Section: A6061 Ram2 Systemmentioning

confidence: 99%

Processability of A6061 Aluminum Alloy Using Laser Powder Bed Fusion by In Situ Synthesis of Grain Refiners

Rosito

Vanzetti

Padovano

et al. 2023

Metals

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Despite the increasing interest in laser powder bed fusion (LPBF), only a few cast aluminum alloys are available for this process. This study focuses on improving the LPBF processability of the A6061 alloy, which is challenging due to its wide solidification range, the dendritic columnar grain growth, and consequent solidification cracking. To address these issues, in situ-synthesized grain refiners can be used to induce equiaxial grain growth and prevent crack formation. A6061 RAM2 powder—a mixture of A6061, Ti, and B4C—was characterized and processed using a low-power LPBF machine to create an in situ particle-reinforced metal matrix composite. Parameter optimization was performed to evaluate the effect of their variation on the printability of the alloy. Microstructural characterization of the samples revealed that the complete reaction and the synthesis of the ceramic reinforcement did not occur. However, TiAl3 was synthesized during the process and promoted a partial grain refinement, leading to the formation of equiaxial grains and preventing the formation of solidification cracks. The tensile tests carried out on the optimized samples exhibit superior mechanical properties compared to those of A6061 processed through LPBF.

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“…Metal matrix composites (MMCs) are recognized for their potential to enhance the properties of metallic components in structural applications. Moreover, the use is not restricted to only structural applications but also gives new functionality such as improved tribological properties, high-temperature application, and electrical conductivity. , MMC materials are extensively employed in various additive manufacturing (AM) methods, including powder bed fusion (PBF), direct ink writing (DIW), stereolithography (SLA), and fused filament fabrication (FFF), etc. − These techniques are chosen based on their compatibility with specific materials. For instance, selective laser melting (SLM) relies on laser-based powder fusion to completely melt materials and construct objects layer by layer.…”

Section: Introductionmentioning

confidence: 99%

Engineering the Interface of Cu-hBN Immiscible System Using 3D Printing To Enhance Mechanical and Thermal Properties

Das,

Katiyar,

Sarkar

et al. 2024

ACS Appl. Eng. Mater.

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Various three-dimensional (3D) printing methods are being employed to optimize results in terms of rapid prototyping, cost-effectiveness, waste reduction, and properties of printed objects, among other factors. The use of composite materials in 3D printing significantly enhances mechanical, wear, and thermal properties. However, when dealing with thermodynamically immiscible composite systems, maintaining a homogeneous dispersion can be challenging. To address this challenge, two techniques have been utilized for the copper (Cu)-hexagonal boron nitride(hBN) immiscible system: one is laser melting-based, i.e., selective laser melting (SLM), and the other is ink-based printing, i.e., direct ink writing (DIW) with postprocessing sintering of the printed object to tailor the dispersion and interface between copper and hexagonal boron nitride (hBN). To facilitate the DIW process, a customized Cu-hBN composite ink was meticulously prepared by optimizing its rheological properties. Similarly, a mechanical mixture of copper and hexagonal boron nitride pellets underwent laser melting to form solid objects. Optical and scanning electron microscopy techniques reveal the surface morphology and the good distribution of hexagonal boron nitride within the copper matrix in both cases. The mechanical properties of the composites were assessed through micro-Vickers hardness testing, compression tests, and tribological analysis. Compression fracture morphologies of both processing techniques were examined. Through the SLM process, pores can be eradicated, whereas in the DIW process, the pore size can be tailored through DIW parameters and subsequent sintering parameters. Both selective laser melting and direct ink writing processed Cu-hBN composites show improved electrical conductivity compared with pure copper. Direct ink writing processed 2 wt %hBN shows better thermal conductivity than other investigated composites. Among selective laser melting and direct ink writing composites, Cu-1 wt %hBN shows higher YS of 32 and 22 MPa, respectively.

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On the Role of Interfacial Reactions, Dissolution and Secondary Precipitation During the Laser Additive Manufacturing of Metal Matrix Composites: A Review

Cited by 13 publications

References 98 publications

Characterization of Composite Powder Feedstock from Powder Bed Fusion Additive Manufacturing Perspective

Characterization of Composite Powder Feedstock from Powder Bed Fusion Additive Manufacturing Perspective

Processability of A6061 Aluminum Alloy Using Laser Powder Bed Fusion by In Situ Synthesis of Grain Refiners

Engineering the Interface of Cu-hBN Immiscible System Using 3D Printing To Enhance Mechanical and Thermal Properties

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