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<p>Additive friction extrusion deposition (AFED) has emerged as a promising solid-state manufacturing method for 3D printing of high-strength aluminum-based alloys and composites. However, the occurrence of abnormal grain growth in the AFED Al-Cu-Mg alloys during post-processing solid solution heat treatment often leads to significant degradation in tensile strength and ductility. To address this issue, 1.5 vol% carbon nanotubes (CNTs) were incorporated into 2009Al to form composite feedstocks for AFED. Microstructural characterization revealed that, in addition to CNTs, dispersed MgAl<sub>2</sub>O<sub>4</sub> nanoparticles formed by the reaction between the introduced oxygen and matrix alloy were also observed in the AFED CNT/2009Al. Quantitative analysis showed that the presence of 3.3 vol% dispersed nanoparticles led to a high pinning parameter of 0.71, situating the AFED CNT/2009Al within the no grain growth zone of the Humphreys’ grain growth model. As a result, the AFED CNT/2009Al exhibited significantly enhanced grain thermal stability and tensile strength. Different from the conventional strategy that increases strength by grain refinement, the strength of the AFED CNT/2009Al was further enhanced by increasing the tool rotation rate during AFED for obtaining a moderately coarser grain structure with a higher proportion of intragranular nanoparticles. The ultimate tensile strength and ductility of the AFED CNT/2009Al were increased from 562&#xa0;MPa and 5.7% to 573&#xa0;MPa and 13.5%, respectively, attributable to significantly increased strain hardening rates and alleviated strain concentration. These findings offer a new pathway for developing advanced nanocomposites with an exceptional strength-ductility synergy.</p>

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Solid-state additive manufacturing of carbon nanotube reinforced Al-Cu-Mg composites with enhanced grain thermal stability and strength-ductility synergy

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年1月22日

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  • H. Zeng,
  • F. C. Liu,
  • Y. D. Wang,
  • Z. Y. Liu,
  • J. X. Yang,
  • P. Xue,
  • Z. Zhang,
  • L. H. Wu,
  • H. Zhang,
  • D. R. Ni,
  • B. L. Xiao,
  • Z. Y. Ma

摘要

Additive friction extrusion deposition (AFED) has emerged as a promising solid-state manufacturing method for 3D printing of high-strength aluminum-based alloys and composites. However, the occurrence of abnormal grain growth in the AFED Al-Cu-Mg alloys during post-processing solid solution heat treatment often leads to significant degradation in tensile strength and ductility. To address this issue, 1.5 vol% carbon nanotubes (CNTs) were incorporated into 2009Al to form composite feedstocks for AFED. Microstructural characterization revealed that, in addition to CNTs, dispersed MgAl2O4 nanoparticles formed by the reaction between the introduced oxygen and matrix alloy were also observed in the AFED CNT/2009Al. Quantitative analysis showed that the presence of 3.3 vol% dispersed nanoparticles led to a high pinning parameter of 0.71, situating the AFED CNT/2009Al within the no grain growth zone of the Humphreys’ grain growth model. As a result, the AFED CNT/2009Al exhibited significantly enhanced grain thermal stability and tensile strength. Different from the conventional strategy that increases strength by grain refinement, the strength of the AFED CNT/2009Al was further enhanced by increasing the tool rotation rate during AFED for obtaining a moderately coarser grain structure with a higher proportion of intragranular nanoparticles. The ultimate tensile strength and ductility of the AFED CNT/2009Al were increased from 562 MPa and 5.7% to 573 MPa and 13.5%, respectively, attributable to significantly increased strain hardening rates and alleviated strain concentration. These findings offer a new pathway for developing advanced nanocomposites with an exceptional strength-ductility synergy.