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In Situ Reactive Printing of Aluminum Matrix Composite with Ultra-High Volume Fraction Reinforcement
1Sibley School of Mechanical and Aerospace Engineering, Cornell University, Ithaca, New York, USA.
3D Printing and Additive Manufacturing
|May 1, 2024
Summary
Additive manufacturing (AM) of aluminum is challenging due to its thermal properties. In situ reactive printing (IRP) with titanium addition successfully created aluminum matrix composites (AMCs) with high reinforcement and improved stiffness.
Area of Science:
- Materials Science
- Additive Manufacturing
- Composite Materials
Background:
- Additive manufacturing (AM) enables complex structures but struggles with aluminum due to its high reflectivity and thermal instability.
- Existing aluminum matrix composites (AMCs) fabricated conventionally have limited reinforcement and part complexity.
- Lightweight structural materials are needed for intermediate temperature ranges, a gap current AM aluminum alloys do not fill.
Purpose of the Study:
- To investigate the use of in situ reactive printing (IRP) for fabricating aluminum matrix composites (AMCs).
- To assess the impact of titanium addition on aluminum feedstock for IRP.
- To evaluate the processability, microstructure, and mechanical properties of the resulting AMCs.
Main Methods:
- Utilized in situ reactive printing (IRP), a novel additive manufacturing technique.
- Employed a dissimilar elemental powder mix of aluminum and titanium.
- Systematically studied the effects of titanium addition on material processability, microstructure, and mechanical performance.
Main Results:
- IRP successfully overcame the incompatibility of aluminum with laser-based AM.
- Fabricated AMCs with an ultra-high volume fraction of intermetallic reinforcement.
- Achieved exceptional stiffness enhancement compared to existing AM aluminum alloys and AMCs.
Conclusions:
- In situ reactive printing (IRP) is a viable method for producing high-performance AMCs from aluminum.
- Titanium addition to aluminum feedstock enables the creation of AMCs with superior properties via IRP.
- This approach addresses the limitations of conventional AM for aluminum and provides advanced lightweight materials.
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