Additive Manufacturing Of Metal Matrix Composites: Enhancing The Printability Of High-Strength Aluminum And Meeting MMC Demand

High-strength aluminum alloys are ideal for lightweight structural applications; however, they remain challenging to process via laser powder bed fusion (LPBF) due to solidification cracking and poor printability. This work addresses these challenges by utilizing micron-scale reactive additives that form submicron inoculant phases in-situ during the LPBF process. This formation of ceramic reinforcements promotes heterogeneous nucleation and significant grain refinement. Two aluminum metal matrix composite systems, A1000-RAM10 and A2024-RAM2, were investigated to characterize their physical, microstructural, and mechanical behaviors which are essential for their broader industrial adoption. The results demonstrate that in-situ inoculants effectively suppress hot tearing, enabling the fabrication of dense, crack-free components. These findings highlight the effectiveness of in-situ synthesizing technology in expanding the alloy design space for additive manufacturing and meeting the demand for high-performance materials.