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<p>This study demonstrates an integrated approach to manufacturing high-performance 3&#xa0;vol.% Al<sub>2</sub>O<sub>3</sub>/FeNi composites by combining gas-solid atomized composite powders with selective laser melting (SLM). An L16 Taguchi orthogonal array was employed to optimize the laser power (<i>P</i>, 190–250&#xa0;W), scanning speed (<i>V</i>, 600–750&#xa0;mm/s), and hatch spacing (<i>H</i>, 90–105&#xa0;μm) for maximizing relative density (RD). The optimal parameter set (<i>P</i> = 250&#xa0;W, <i>V</i> = 650&#xa0;mm/s, <i>H</i> = 100&#xa0;μm) yielded a near-full densification of 99.31 ± 0.06%. Microstructural analysis revealed a homogeneous dispersion of Al<sub>2</sub>O<sub>3</sub> particles within the FeNi matrix, which exhibited a hybrid structure of epitaxial columnar, equiaxed, and sub-equiaxed crystals. XRD confirmed that the matrix was primarily composed of the <i>γ</i> (Fe, Ni) phase. The optimally processed sample achieved a peak hardness of 222.38 ± 2.00 HV<sub>0.1</sub>, a low coefficient of friction (COF) of 0.45 ± 0.012, and a wear rate of 8.45 × 10<sup>−5</sup> ± 0.21&#xa0;mm<sup>3</sup>N<sup>−1</sup>&#xa0;m<sup>−1</sup>. These tribological properties represent a significant improvement, corresponding to reductions in the COF and wear rate of 31.82 ± 3.2% and 36.56 ± 2.4%, respectively, compared to samples fabricated under non-optimal SLM parameters.</p>

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Effect of Process Parameters on the Microstructure and Properties of Al2O3/FeNi Composite via Selective Laser Melting from Gas-Solid Atomized Powders

  • 期刊论文

  • 发表日期：

    2025年11月10日

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  • Yandan Xia,
  • Guixiang Zhang,
  • Jinli Xiang,
  • Lianfang Jin,
  • Haozhe Zhang,
  • Linzhi Jiang

摘要

This study demonstrates an integrated approach to manufacturing high-performance 3 vol.% Al2O3/FeNi composites by combining gas-solid atomized composite powders with selective laser melting (SLM). An L16 Taguchi orthogonal array was employed to optimize the laser power (P, 190–250 W), scanning speed (V, 600–750 mm/s), and hatch spacing (H, 90–105 μm) for maximizing relative density (RD). The optimal parameter set (P = 250 W, V = 650 mm/s, H = 100 μm) yielded a near-full densification of 99.31 ± 0.06%. Microstructural analysis revealed a homogeneous dispersion of Al2O3 particles within the FeNi matrix, which exhibited a hybrid structure of epitaxial columnar, equiaxed, and sub-equiaxed crystals. XRD confirmed that the matrix was primarily composed of the γ (Fe, Ni) phase. The optimally processed sample achieved a peak hardness of 222.38 ± 2.00 HV0.1, a low coefficient of friction (COF) of 0.45 ± 0.012, and a wear rate of 8.45 × 10−5 ± 0.21 mm3N−1 m−1. These tribological properties represent a significant improvement, corresponding to reductions in the COF and wear rate of 31.82 ± 3.2% and 36.56 ± 2.4%, respectively, compared to samples fabricated under non-optimal SLM parameters.