Hierarchical Analysis of Phase Constituent and Mechanical Properties of AlSi10Mg/SiC Composite Produced by Laser-Based Powder Bed Fusion

Aluminum matrix composites reinforced with ceramic particles have recently received considerable research interest owing to their light weight, high modulus, and high strength. This study fabricated SiC reinforced Al–10 wt%Si–0.35 wt% Mg (AlSi10Mg) alloy matrix composites with high relative density using a laser-based powder bed fusion (LPBF) process. The reaction phase of Al4SiC4 from the interface of the SiC particles occurred under LPBF and its fraction increased with increasing energy density. A high compressive stress of >600 MPa was obtained for the AlSi10Mg/SiC composite produced via LPBF at an optimum energy density (250 J/mm3). This study analyzed the mechanical properties of the LPBF composite hierarchically from micro to macro levels. A higher Young’s modulus (evaluated using a compression test) was obtained for the AlSi10Mg/SiC composite fabricated using LPBF than the AlSi10Mg alloy. From the micro level analysis on mechanical properties, the increased Al4SiC4 formation with an increase in energy density improved the hardness and Young’s modulus compared to those of the AlSi10Mg alloy. However, SiC in the composite is more effective for being high strength and Young’s modulus than Al4SiC4.