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<p>Al<sub>2</sub>O<sub>3</sub>/FeNi composites were successfully fabricated via gas-solid atomization and laser powder bed fusion (LPBF). This study investigated the influence of Al<sub>2</sub>O<sub>3</sub> content (0, 3, and 8 vol.%) on densification, microstructure, mechanical properties, and wear behavior. The results demonstrated that the relative density (RD) slightly decreased from 99.83 ± 0.46% to 98.24 ± 0.35% as the Al<sub>2</sub>O<sub>3</sub> volume content increased to 8 vol.%, yet remained at a high level. Microstructural analysis revealed that the uniformly dispersed Al<sub>2</sub>O<sub>3</sub> particles within the FeNi matrix promoted grain refinement, promoting a transition from a columnar to a fine equiaxed grain morphology. Mechanical property tests revealed that the 8 vol.% Al<sub>2</sub>O<sub>3</sub>/FeNi composites have significantly higher microhardness, ultimate tensile strength, and yield strength than the FeNi sample, achieving values of 234.25 ± 3.54 HV<sub>0.1</sub>, 589 ± 8&#xa0;MPa, and 435 ± 11&#xa0;MPa, respectively. The elongation is reasonably reduced to 15.0%. Simultaneously, the wear resistance was improved, evidenced by a low average friction coefficient of 0.36 ± 0.05 and a reduction in wear rate of approximately 60%.</p>

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Investigation of Microstructure, Mechanical and Tribological Properties of Al2O3/FeNi Composite Fabricated by Laser Powder Bed Fusion from Gas-Solid Atomized Powders

  • 期刊论文

  • 发表日期：

    2026年1月27日

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

摘要

Al2O3/FeNi composites were successfully fabricated via gas-solid atomization and laser powder bed fusion (LPBF). This study investigated the influence of Al2O3 content (0, 3, and 8 vol.%) on densification, microstructure, mechanical properties, and wear behavior. The results demonstrated that the relative density (RD) slightly decreased from 99.83 ± 0.46% to 98.24 ± 0.35% as the Al2O3 volume content increased to 8 vol.%, yet remained at a high level. Microstructural analysis revealed that the uniformly dispersed Al2O3 particles within the FeNi matrix promoted grain refinement, promoting a transition from a columnar to a fine equiaxed grain morphology. Mechanical property tests revealed that the 8 vol.% Al2O3/FeNi composites have significantly higher microhardness, ultimate tensile strength, and yield strength than the FeNi sample, achieving values of 234.25 ± 3.54 HV0.1, 589 ± 8 MPa, and 435 ± 11 MPa, respectively. The elongation is reasonably reduced to 15.0%. Simultaneously, the wear resistance was improved, evidenced by a low average friction coefficient of 0.36 ± 0.05 and a reduction in wear rate of approximately 60%.