| Abstract Scope |
The thermomechanical properties of particle-reinforced metal matrix composites (MMCs) are attractive for high-performance defense and space applications, but fabrication of MMC components with conventional methods is difficult, costly, and typically limited to components with simple geometry. Additively manufacturing particulate MMCs with laser powder bed fusion (LPBF) would be an ideal method, but the laser consolidation of these materials has been unsuccessful in matching the properties of conventionally-produced MMCs. The challenges include hot cracking of the matrix, spreading the heterogeneous powder, distributing small ceramic particles, and forming a strong bond between the metal and the ceramic. Here, by mechanically alloying high-strength aluminum alloys and ceramic particles, we manufacture aluminum composite powders with morphology tuned for AM process conditions. Using LPBF, we achieve dense consolidation of these powders and demonstrate the potential for highly-reinforced, high-strength aluminum alloys to be used in applications requiring complex geometries, short lead times, or low part numbers. |