Fabrication of AlSi10Mg–AlN metal matrix composites using laser powder bed fusion technology

AlSi10Mg has evolved to become a standard aluminium alloy utilised in additive manufacturing (AM), owing to a robust response to processing and desirable properties such as a high-strength-weight ratio. Despite these promising traits, the stiffness, thermal conductivity, and thermal stability of AM AlSi10Mg remain inadequate for certain applications. In an effort to bolster performance in these areas, coupling the alloy with controlled levels of ceramic particulate is under investigation. Specifically, research on the incorporation of aluminium nitride (AlN) additions and how these influence the processability of AlSi10Mg in the context of laser powder bed fusion has been considered. Using a design of experiments (DOE) approach, the effects of AlN concentration, laser power, scan speed, and hatch spacing on final part density were studied. The optimal range of VED was determined to be 60–80 J/mm3 for all chemistries considered. However, the presence of AlN was found to reduce as-built density as the ceramic concentration increased. AlN remained largely unaffected by laser irradiation.