Selective laser melting of aluminum-alumina powder composites obtained by hydrothermal oxidation method
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Selective laser melting of aluminum‑alumina powder composites obtained by hydrothermal oxidation method Anton Yu. Nalivaiko1 · Dmitriy Yu. Ozherelkov1 · Alexey N. Arnautov2 · Sergey V. Zmanovsky2 · Alexandra A. Osipenkova1 · Alexander A. Gromov1 Received: 13 June 2020 / Accepted: 26 September 2020 © Springer-Verlag GmbH Germany, part of Springer Nature 2020
Abstract Selective laser melting of Al-Al2O3 core–shell composite with 10 wt.% of alumina was studied. The initial powder was obtained by hydrothermal oxidation of aluminum powder. A matrix of parameters was selected for selective laser melting of composites, including laser power from 180 to 220 W, scanning speed from 180 to 220 mm/s, and hatch spacing from 0.13 to 0.18 mm. The type of microstructure, relative density, and hardness of synthesized objects were determined. The influence of the laser’s areal energy density on the properties of synthesized objects was studied. Depending on the EDa used, different types of microstructure were formed. The E Da within the range 7–8 J/mm2 was found to be optimal for SLM of Al-10 wt.% Al2O3 core–shell powder composites. Beyond this range, uncomplete powder melting as well as boiling of the aluminum leads to the low density and formation of microcracks after solidification. The hardness of the finest synthesized sample (58.3 ± 0.9 HB) and uniform distribution of alumina was obtained at EDa = 7.69 J/mm2 with the following SLM parameters: P = 220 W; h = 0.13; V = 220 mm/s. Based on the obtained results, further research using SLM with double exposure of the layer with a laser beam was suggested. Keywords Composite materials · Selective laser melting · Core–shell structure · Relative density · Areal energy density
1 Introduction Al-Al2O3 matrix composites are widely used for various applications in aerospace and automotive industries because of their excellent properties, such as their light weight, high specific strength and good wear resistance [1–3]. Production of functional components for the needs of such high-technology industries is always a challenge. Rapid development of additive manufacturing technologies, such as selective laser melting (SLM), offers a high potential in the fabrication of advanced complex-shaped engineering components from Al-Al2O3 composites with superfine microstructures, high strength and stiffness, such as automobile engine pistons, cylinder liners and brake drums [4].
* Anton Yu. Nalivaiko [email protected] 1
KINETICA Engineering Center, National University of Science and Technology MISIS (NUST MISIS), Leninsky ave 4, Moscow 119991, Russia
UC RUSAL, Moscow, Russia
2
Recently, the Al-Al2O3 [5] composites prepared by the high energy ball milling have been fabricated by the SLM process, showing the significantly enhanced microhardness and wear resistance. Studies have shown that the strength of Al-Al2O3 composites increases with the volume fraction of Al2O3. However, the strengthening effect is significantly determined by the particle size and found
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