Effect of ceramic particle size on densification behavior, microstructure formation, and performance of TiB2-reinforced Al-based composites prepared by selective laser melting

Al-based composites with micrometer and submicro-TiB2 reinforcements (1 wt%) have been produced by selective laser melting (SLM) from mixed powder under different processing conditions. The results show that the densification level of SLM-processed composite with submicro-TiB2 particles (>99.0%) was 0.3–2.4% larger than that of micrometer TiB2-reinforced composite under the same processing conditions. The distribution of Si precipitates in the matrix experienced a transform from continuous cellular to directional line-like morphology with reinforcement size decreasing from micron to submicron. The reinforcement size added in the matrix also exhibited a critical influence on preferred orientation and grain size of matrix. The SLM-processed composites exhibited improved tensile strength and ductility with a decrease of reinforcement size. High tensile strength of ∼400 MPa and elongation of ∼3.6% were obtained for the fine TiB2-reinforced samples, increasing by 6 and 13% compared with that of micro-TiB2–added samples, respectively.