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<p>Aluminum matrix composites based on AlSi10Mg alloy reinforced with 1 and 5 wt% tungsten carbide (WC) nanoparticles were fabricated using a two-step approach: planetary ball milling for powder preparation and laser powder bed fusion (LPBF) for additive manufacturing. The milling process enabled adhesion of WC nanoparticles to the surface of spherical AlSi10Mg particles, preserving powder flowability suitable for LPBF. XRD, EDS, and Raman spectroscopy were employed to study the phase evolution during printing, which confirmed the decomposition of WC under laser exposure, accompanied by the formation of secondary phases such as metastable β-W and intermetallic Al<sub>12</sub>W, with no residual WC or W<sub>2</sub>C observed in the printed material. Mechanical testing showed that the 1 wt% WC composite exhibited a high ultimate tensile strength of about 400&#xa0;MPa and 4% elongation. Fractographic analysis revealed ductile failure mechanisms with dimple formation and second-phase particle-induced void nucleation. These findings highlight the influence of ceramic content on microstructure, phase formation, and mechanical behavior of LPBF-processed AlSi10Mg/WC composites. The resulting composite is a potential material for aerospace, nuclear, and space applications, where its combination of structural integrity and integrated radiation shielding is important.</p>

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Microstructure and phase composition of AlSi10Mg composites with nano-tungsten carbide fabricated by laser powder bed fusion of surface-modified powders

  • 期刊论文

  • 发表日期：

    2026年1月30日

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  • Andrey Nepapushev,
  • Kirill Kuskov,
  • Stanislav Chernyshikhin,
  • Dmitry Zherebtsov,
  • Dmitry Moskovskikh

摘要

Aluminum matrix composites based on AlSi10Mg alloy reinforced with 1 and 5 wt% tungsten carbide (WC) nanoparticles were fabricated using a two-step approach: planetary ball milling for powder preparation and laser powder bed fusion (LPBF) for additive manufacturing. The milling process enabled adhesion of WC nanoparticles to the surface of spherical AlSi10Mg particles, preserving powder flowability suitable for LPBF. XRD, EDS, and Raman spectroscopy were employed to study the phase evolution during printing, which confirmed the decomposition of WC under laser exposure, accompanied by the formation of secondary phases such as metastable β-W and intermetallic Al12W, with no residual WC or W2C observed in the printed material. Mechanical testing showed that the 1 wt% WC composite exhibited a high ultimate tensile strength of about 400 MPa and 4% elongation. Fractographic analysis revealed ductile failure mechanisms with dimple formation and second-phase particle-induced void nucleation. These findings highlight the influence of ceramic content on microstructure, phase formation, and mechanical behavior of LPBF-processed AlSi10Mg/WC composites. The resulting composite is a potential material for aerospace, nuclear, and space applications, where its combination of structural integrity and integrated radiation shielding is important.