Development of an in-situ multi-component reinforced Al-based metal matrix composite by direct metal laser sintering technique — Optimization of process parameters

In the present investigation, an in-situ multi-component reinforced aluminum based metal matrix composite was fabricated by the combination of self-propagating high-temperature synthesis and direct metal laser sintering process. The different mixtures of Al, TiO2 and B4C powders were used to initiate and maintain the self-propagating high-temperature synthesis by laser during the sintering process. It was found from the X-ray diffraction analysis and scanning electron microscopy that the reinforcements like Al2O3, TiC, and TiB2 were formed in the composite. The scanning electron microscopy revealed the distribution of the reinforcement phases in the composite and phase identities. The variable parameters such as powder layer thickness, laser power, scanning speed, hatching distance and composition of the powder mixture were optimized for higher density, lower porosity and higher microhardness using Taguchi method. Experimental investigation shows that the density of the specimen mainly depends upon the hatching distance, composition and layer thickness. On the other hand, hatching distance, layer thickness and laser power are the significant parameters which influence the porosity. The composition, laser power and layer thickness are the key influencing parameters for microhardness. •The reinforcements such as Al2O3, TiC, and TiB2 were produced in Al-MMC through SHS.•The density is mainly influenced by the material composition and hatching distance.•Hatching distance is the major influencing parameter on porosity.•The material composition is the significant parameter to enhance the microhardness.•The SEM micrographs reveal the distribution of TiC, TiB2 and Al2O3 in the composite.