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<p>Multi-material additive manufacturing involves different routes aimed to produce parts with high complexity made by custom materials with unique characteristics. This work deals with a preliminary investigation on the possibility to produce customized materials and structures by mixing different commercially available alloys through a fluidised bed-based premixing system and then use this mixture as feedstock material for L-PBF technology. The addition of 17-4 PH steel and Ti6Al4V ELI alloy in a Cu matrix was considered in this work, pursuing the goal of producing a metal matrix composite (MMC) that combines the excellent thermal conductivity of Cu with the high mechanical properties of the other two alloys meant to act as strengthening phase. Moreover, the use and the printability of complex pre-alloyed powders, such as the Ti6Al4V and the 17-4 PH steel, were chosen aiming to explore how complex these mixtures can be. The main results obtained were evaluated in terms of density, microstructure, chemical composition and microhardness of the specimens. The experimental outcomes suggested that despite the intrinsic differences of the premixed materials, the in situ MMC production through L-PBF was viable with relative densities always greater than 97%, a notable increase in hardness compared to pure Cu and a proper dispersion of the selected alloys in the Cu matrix.</p>

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A Feasibility Analysis of Cu-Matrix Composite In Situ Production through Laser Powder Bed Fusion of Mixed Alloys

  • 期刊论文

  • 发表日期：

    2025年2月4日

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  • Ersilia Cozzolino,
  • Andrea El Hassanin,
  • Domenico Borrelli,
  • Antonio Caraviello,
  • Nicola Sicignano,
  • Antonello Astarita

摘要

Multi-material additive manufacturing involves different routes aimed to produce parts with high complexity made by custom materials with unique characteristics. This work deals with a preliminary investigation on the possibility to produce customized materials and structures by mixing different commercially available alloys through a fluidised bed-based premixing system and then use this mixture as feedstock material for L-PBF technology. The addition of 17-4 PH steel and Ti6Al4V ELI alloy in a Cu matrix was considered in this work, pursuing the goal of producing a metal matrix composite (MMC) that combines the excellent thermal conductivity of Cu with the high mechanical properties of the other two alloys meant to act as strengthening phase. Moreover, the use and the printability of complex pre-alloyed powders, such as the Ti6Al4V and the 17-4 PH steel, were chosen aiming to explore how complex these mixtures can be. The main results obtained were evaluated in terms of density, microstructure, chemical composition and microhardness of the specimens. The experimental outcomes suggested that despite the intrinsic differences of the premixed materials, the in situ MMC production through L-PBF was viable with relative densities always greater than 97%, a notable increase in hardness compared to pure Cu and a proper dispersion of the selected alloys in the Cu matrix.