Effect of process parameters on the density and porosity of laser melted AlSi10Mg/SiC metal matrix composite

doi:10.1007/s11465-018-0521-y

Front. Mech. Eng.

2018, Vol. 13

Issue (4) : 520-527 https://doi.org/10.1007/s11465-018-0521-y

RESEARCH ARTICLE

Effect of process parameters on the density and porosity of laser melted AlSi10Mg/SiC metal matrix composite

Omotoyosi H. FAMODIMU(

), Mark STANFORD, Chike F. ODUOZA, Lijuan ZHANG

Faculty of Science and Engineering, School of Engineering, Telford Campus, University of Wolverhampton, WV1 1LY Wolverhampton, UK

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Abstract

Laser melting of aluminium alloy—AlSi10Mg has increasingly been used to create specialised products in various industrial applications, however, research on utilising laser melting of aluminium matrix composites in replacing specialised parts have been slow on the uptake. This has been attributed to the complexity of the laser melting process, metal/ceramic feedstock for the process and the reaction of the feedstock material to the laser. Thus, an understanding of the process, material microstructure and mechanical properties is important for its adoption as a manufacturing route of aluminium metal matrix composites. The effects of several parameters of the laser melting process on the mechanical blended composite were thus investigated in this research. This included single track formations of the matrix alloy and the composite alloyed with 5% and 10% respectively for their reaction to laser melting and the fabrication of density blocks to investigate the relative density and porosity over different scan speeds. The results from these experiments were utilised in determining a process window in fabricating near-fully dense parts.

Keywords selective laser melting additive manufacturing mechanical alloying powder metallurgy aluminium metal matrix composite

Corresponding Author(s): Omotoyosi H. FAMODIMU

Just Accepted Date: 14 May 2018 Online First Date: 06 June 2018 Issue Date: 31 July 2018

Cite this article:

Omotoyosi H. FAMODIMU,Mark STANFORD,Chike F. ODUOZA, et al. Effect of process parameters on the density and porosity of laser melted AlSi10Mg/SiC metal matrix composite[J]. Front. Mech. Eng., 2018, 13(4): 520-527.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-018-0521-y
https://academic.hep.com.cn/fme/EN/Y2018/V13/I4/520

Tab.1 AlSi10Mg composition [⁹]

Fig.1 Sample of composite particle after mechanical alloying showing SiC particles embedded into the Al-alloy particle

Tab.2 Scanning parameters

Tab.3 Density blocks with variable scan speed

Fig.2 AlSi10Mg-alloy matrix scanned at 800 mm/s

Fig.3 Scan line of the 10% reinforced AlSi10Mg/SiC_p composite scanned at Mag 750× (a) 640 mm/s, (b) 720 mm/s, (c) 800 mm/s, (d) 880 mm/s, and (e) 960 mm/s

Fig.4 Scan line of the 5% reinforced AlSi10Mg/SiC_p composite scanned at Mag 750× (a) 640 mm/s, (b) 720 mm/s, (c) 800 mm/s, (d) 880 mm/s, and (e) 960 mm/s

Fig.5 Width of scanned tracks in relation to scanning speed

Fig.6 Relative density (RD) and percentage porosity from image analysis (IA)

Fig.7 Images of samples in the z-direction at 5% Al-MMC (a) 640 mm/s, (b) 720 mm/s, (c) 800 mm/s, (d) 880 mm/s, and (e) 960 mm/s

Fig.8 Images of samples in the z-direction at 10% Al-MMC (a) 640 mm/s, (b) 720 mm/s, (c) 800 mm/s, (d) 880 mm/s, and (e) 960 mm/s

Fig.9 Microstructure of as-built samples taken at magnification: 500× and 20000×. (a?b) Matrix alloy; (c?d) 5% Al-MMC; (e?f) 10% Al-MMC

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