Work

Overcoming Processability Limitations in Al6082 Alloy by Using Laser Powder Bed Fusion of Aluminum Matrix Composites with Titanium Carbide/Silicon Carbide Reinforcements

Year: 2025

Type: article

Abstract: The use of aluminum alloys in aerospace is limited by their poor weldability, making many incompatible with additive manufacturing (AM) processes like powder bed fusion—laser beam metal (PBF-LB/M), known as well as laser powder bed fusion. This incompatibility hinders the fabrication of complex, lightweight components. To overcome this, Aluminum Metal Matrix Composites (AMMCs) are formed by mechanically alloying the non-processable Al6082 base alloy with ceramic reinforcements; subsequently, Titanium Carbide (TiC) and Silicon Carbide (SiC) particles are developed. This approach induces microstructural changes necessary for AM compatibility. The influence of varying reinforcement contents (1–5 wt.%) on powder homogeneity, microstructural evolution (via Energy Dispersive X-ray Spectroscopy and Electron Backscatter Diffraction), processability, and mechanical properties is systematically studied. The key finding is that metallurgical modification is a robust solution. TiC addition at 2 wt.% and 5 wt.% completely eliminated solidification cracking, achieving high processability. SiC substantially reduced cracking compared to the base alloy. These results demonstrate the potential of AMMCs to successfully translate conventional, non-weldable aluminum alloys into the realm of advanced additive manufacturing.

Source: Metals

DOI: 10.3390/met15111232

Authors: Raúl Gómez, Maria San Sebastian, Teresa Guraya, Ane Miren Mancisidor

Institutions: IK4-Lortek, University of the Basque Country

Language: English

Topic: Additive Manufacturing Materials and Processes

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

SDG: Industry, innovation and infrastructure

Open Access status: gold

Estimated APC paid: $3,137