The present study has proved the feasibility to produce the bulk-form TiC/AlSi10Mg nanocomposite parts with the novel reinforcing morphology and enhanced mechanical properties by selective laser melting (SLM) additive manufacturing (AM) process. The influence of linear laser energy density (η) on the microstructural evolution and mechanical performance (e.g., densification level, microhardness, wear and tribological properties) of the SLM-processed TiC/AlSi10Mg nanocomposite parts was comprehensively studied, in order to establish an in-depth relationship between SLM process, microstructures, and mechanical performance. It showed that the TiC reinforcement in the SLM-processed TiC/AlSi10Mg nanocomposites experienced an interesting microstructural evolution with the increase of the applied η. At an elevated η above 600 J/m, a novel regularly distributed ring structure of nanoscale TiC reinforcement was tailored in the matrix due to the unique metallurgical behavior of the molten pool induced by the operation of Marangoni flow. The near fully dense TiC/AlSi10Mg nanocomposite parts (>98.5% theoretical density (TD)) with the formation of ring-structured reinforcement demonstrated outstanding mechanical properties. The dimensional accuracy of SLM-processed parts well met the demand of industrial application with the shrinkage rates of 1.24%, 1.50%, and 1.72% in X, Y, and Z directions, respectively, with the increase of η to 800 J/m. A maximum microhardness of 184.7 HV0.1 was obtained for SLM-processed TiC/AlSi10Mg nanocomposites, showing more than 20% enhancement as compared with SLM-processed unreinforced AlSi10Mg part. The high densification response combined with novel reinforcement of SLM-processed TiC/AlSi10Mg nanocomposite parts also led to the considerably low coefficient of friction (COF) of 0.28 and wear rate of 2.73 × 10−5 mm3 · N−1 · m−1. The present work accordingly provides a fundamental understanding of the tailored forming of lightweight multiple nanocomposite materials system by laser AM.
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February 2016
Research-Article
Laser Additive Manufacturing of Novel Aluminum Based Nanocomposite Parts: Tailored Forming of Multiple Materials
Dongdong Gu,
Dongdong Gu
College of Materials Science and Technology,
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Institute of Additive Manufacturing (3D Printing),
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
e-mail: dongdonggu@nuaa.edu.cn
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
e-mail: dongdonggu@nuaa.edu.cn
Search for other works by this author on:
Hongqiao Wang,
Hongqiao Wang
College of Materials Science and Technology,
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Institute of Additive Manufacturing (3D Printing),
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
Search for other works by this author on:
Donghua Dai
Donghua Dai
College of Materials Science and Technology,
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Institute of Additive Manufacturing (3D Printing),
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
Search for other works by this author on:
Dongdong Gu
College of Materials Science and Technology,
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Institute of Additive Manufacturing (3D Printing),
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
e-mail: dongdonggu@nuaa.edu.cn
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
e-mail: dongdonggu@nuaa.edu.cn
Hongqiao Wang
College of Materials Science and Technology,
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Institute of Additive Manufacturing (3D Printing),
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
Donghua Dai
College of Materials Science and Technology,
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Institute of Additive Manufacturing (3D Printing),
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
Nanjing University of Aeronautics
and Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
1Corresponding author.
Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received November 21, 2014; final manuscript received March 28, 2015; published online September 9, 2015. Assoc. Editor: Z. J. Pei.
J. Manuf. Sci. Eng. Feb 2016, 138(2): 021004 (11 pages)
Published Online: September 9, 2015
Article history
Received:
November 21, 2014
Revision Received:
March 28, 2015
Citation
Gu, D., Wang, H., and Dai, D. (September 9, 2015). "Laser Additive Manufacturing of Novel Aluminum Based Nanocomposite Parts: Tailored Forming of Multiple Materials." ASME. J. Manuf. Sci. Eng. February 2016; 138(2): 021004. https://doi.org/10.1115/1.4030376
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