| Abstract Scope |
The stiffness, strength, and thermal stability 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 largely unsuccessful in matching the properties of conventionally-produced MMCs. Here, by mechanically alloying AlSi10Mg powder and ceramic microparticles, we manufacture highly-reinforced aluminum composite powders with morphology optimized for AM process conditions. The ceramic content, chemistry, and particle size are varied. Using LPBF, we achieve dense consolidation of these powders at ceramic contents of up to 30% and demonstrate tensile properties matching the properties of composites made by conventional methods. |