Enhancement of grain refinement and heat resistance in TiB2-reinforced Al-Cu-Mg-Fe-Ni matrix composite additive manufactured by electron beam melting

Additive manufacturing (AM) by electron beam melting (EBM) has many advantages over the laser-based AM techniques, but is subjected to a lower cooling rate and a long time thermal exposure with a much higher temperature. Therefore, the EBMed aluminum alloys commonly have coarser solidification structures such that lower mechanical properties compared to their SLMed counterparts. In this work, we proposed a strategy of introducing TiB2 particles into heat-resistant Al-Cu-Mg-Fe-Ni alloy to enhance the grain refinement and heat resistance for EBM fabrication. Applying a “presintering-densification” scanning strategy, near fully dense samples were build up with precise contours and good surface quality. The as-built EBMed TiB2/Al-Cu-Mg-Fe-Ni composite possessed a highly homogeneous microstructure with uniformly distributed TiB2 and Fe/Ni rich intermetallic particles. A fully equiaxed grain structure was achieved in the composite with a profoundly refined grain size of ~9 µm. The improved grain refinement effect was attributed to the sufficient activation of TiB2 particles as heterogeneous nuclei under a high cooling rate. Additionally, the solidified microstructure has shown an excellent thermal stability under ~500 °C during EBM process. The coexistence of thermal stable TiB2 and Fe, Ni-rich intermetallics at grain boundaries restricted the grain growth effectively. The as-built composite exhibited a high tensile strength of 253.4 MPa with an outstanding elongation of 13.5 %. After a T6-like heat treatment, the tensile strength was increased to 322 MPa with an elongation of 9.8 %. This study might shed a new light on designing high performance aluminum alloys/composites suitable for EBM technique. [Display omitted] •A TiB2/Al-Cu-Mg-Fe-Ni composite was additive manufactured by electron beam melting.•A high microstructural homogeneity is exhibited all over the building part.•The composite shows much smaller grains and superior strength than EBM Al alloys.•Microstructure of the composite shows excellent thermal stability during EBM.