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<p>Metal matrix composites (MMCs) reinforced with a low volume fraction of ceramic particles can achieve superior properties when produced by laser powder bed fusion (LPBF, also known as selective laser melting, SLM). A key challenge, however, is preparing feedstock with uniform reinforcement dispersion and minimal contamination. This work systematically compares three powder-mixing routes—rolling, tumbling, and a hybrid wet-mixing process—to fabricate LPBF TiN/AISI 420 composites containing 1&#xa0;wt.% TiN and 99&#xa0;wt.% AISI 420. We evaluate powder morphology, surface quality, relative density, microstructure, hardness, tensile behavior, and corrosion resistance. Rolling led to pronounced TiN agglomeration, while tumbling introduced surface contamination of the steel matrix, and both degraded build quality and properties. In contrast, the hybrid wet-mixing route (ultrasonic dispersion in hexane followed by mechanical stirring and solvent removal) yielded the most uniform powder with minimal agglomeration. LPBF specimens prepared from the hybrid route achieved the best overall performance: surface roughness S<sub>a</sub> = 4.6 ± 0.3&#xa0;µm, relative density 99.4 ± 0.2%, hardness 720 ± 12&#xa0;HV, tensile strength 1779 ± 50&#xa0;MPa with elongation 6.1 ± 0.3%, and a 48&#xa0;h FeCl<sub>3</sub> corrosion rate of 112.6 ± 0.6&#xa0;mm/year. These results demonstrate that careful feedstock preparation is essential to exploit the benefits of ceramic reinforcement in LPBF stainless-steel MMCs.</p>

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Effect of Feedstock Preparation on the Performance of Laser Powder Bed Fused TiN/AISI 420 Composites

  • 期刊论文

  • 发表日期：

    2026年7月20日

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  • Duc Tran,
  • Jeng-Rong Ho,
  • Huu-Nhan Tran,
  • Quang-Lam Tran

摘要

Metal matrix composites (MMCs) reinforced with a low volume fraction of ceramic particles can achieve superior properties when produced by laser powder bed fusion (LPBF, also known as selective laser melting, SLM). A key challenge, however, is preparing feedstock with uniform reinforcement dispersion and minimal contamination. This work systematically compares three powder-mixing routes—rolling, tumbling, and a hybrid wet-mixing process—to fabricate LPBF TiN/AISI 420 composites containing 1 wt.% TiN and 99 wt.% AISI 420. We evaluate powder morphology, surface quality, relative density, microstructure, hardness, tensile behavior, and corrosion resistance. Rolling led to pronounced TiN agglomeration, while tumbling introduced surface contamination of the steel matrix, and both degraded build quality and properties. In contrast, the hybrid wet-mixing route (ultrasonic dispersion in hexane followed by mechanical stirring and solvent removal) yielded the most uniform powder with minimal agglomeration. LPBF specimens prepared from the hybrid route achieved the best overall performance: surface roughness Sa = 4.6 ± 0.3 µm, relative density 99.4 ± 0.2%, hardness 720 ± 12 HV, tensile strength 1779 ± 50 MPa with elongation 6.1 ± 0.3%, and a 48 h FeCl3 corrosion rate of 112.6 ± 0.6 mm/year. These results demonstrate that careful feedstock preparation is essential to exploit the benefits of ceramic reinforcement in LPBF stainless-steel MMCs.