Key Takeaways & Executive Findings
- •• Spray granulation produces spherical SiCP/AlSi10Mg composite powders with improved flowability, overcoming limitations of conventional mechanical mixing. • In-situ reaction during LPBF forms Al4SiC4 reinforcing phases, enabling a mixed strengthening mechanism with residual SiCP. • Optimizing laser power (310 W) minimizes porosity and achieves superior microhardness (265.38 HV) and wear resistance. • The fabricated composites exhibit enhanced hardness compared to AlSi10Mg and other reported SiCP/AlSi10Mg composites with similar SiC volume fractions.
Abstract
Additive manufacturing (AM) of SiCP/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 SiCP/AlSi10Mg composite powders prepared by spray granulation were employed to fabricate SiCP-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 SiCP 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 SiCP to Al4SiC4, micro-defects could be effectively limited, and wear performance could be improved. Consequently, with an optimized ratio of SiCP to Al4SiC4, the composite exhibited a mixed strengthening mechanism caused by the SiCP 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 SiCP/AlSi10Mg composites with similar volume fractions using the mixed powders.
1. Introduction
AlSi10Mg alloy, renowned for its exceptional ductility, high electrical and thermal conductivity, low coefficient of thermal expansion, and superior castability, has found extensive application in the aerospace and automotive industries [1, 2]. However, its relatively low hardness and poor wear resistance restrict its application in severe wear environments, including bearings and brake systems. To this end, particle-reinforced aluminum matrix composites (PR-AMCs), which offer high specific modulus, thermal conductivity, and excellent wear performance, have emerged as a significant research direction [3, 4]. Commonly employed particle reinforcements include SiC, TiC, WC, and Al2O3, among which SiC is often utilized as a ceramic particle reinforcement material due to its high elastic modulus and hardness. More interestingly, SiC can react with the aluminum matrix to form an additional reinforced phase Al4SiC4, thus obtaining a mixed strengthening mechanism coupled with the remaining SiCP [5, 6].
The existing production methods for aluminum alloys contain powder metallurgy methods [7], liquid sintering methods [8], and solid sintering methods. Nevertheless, their internal drawbacks such as long design cycles and fixed shape limit the related production of complex-shaped components for engineering applications [9, 10]. Thus, new manufacturing methods are urgently needed.
As one of the rapidly developing technologies in recent years, LPBF boasts numerous advantages in terms of rapid cooling for fine grains and flexibly controllable building for complex-shaped components. The prepared parts can meet the requirements for broad applicability, high part quality, and high density [11, 12]. It brings new concepts in material development [13−15].
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GONG Zi-yi, YE Nan, WU Zi-chun, MAO Jie, TANG Jian-cheng, ZHUO Hai-ou, XU Cheng-rui (2025). Microstructure and wear property of SiCP/AlSi10Mg composites prepared by laser powder bed fusion. Journal of Central South University. https://doi.org/10.1007/s11771-025-6121-1
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Frequently Asked Questions
What is the main advantage of using spray granulation for SiCP/AlSi10Mg composite powders?
Spray granulation produces spherical composite powders with improved flowability and reduced agglomeration, which are critical for consistent laser powder bed fusion processing.
How does laser power affect the microstructure and wear properties of the composites?
Adjusting laser power (270-350 W) changes the ratio of SiCP to in-situ formed Al4SiC4, influencing micro-defect formation and wear performance. Optimal laser power (310 W) minimizes porosity and enhances hardness and wear resistance.
What is the role of Al4SiC4 in the composite?
Al4SiC4 is an in-situ formed reinforcing phase that contributes to a mixed strengthening mechanism with residual SiCP, improving hardness and wear resistance.
How does the hardness of the optimized composite compare to other reported materials?
At 310 W, the composite achieved a microhardness of 265.38 HV, which is superior to AlSi10Mg and other reported SiCP/AlSi10Mg composites with similar SiC volume fractions fabricated using mixed powders.
What are the potential applications of these SiCP/AlSi10Mg composites?
Due to their enhanced hardness and wear resistance, these composites are suitable for severe wear environments such as bearings and brake systems in aerospace and automotive industries.
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