Enhancement of mechanical, surface, and thermal properties of graphene reinforced aluminum metal matrix manufactured by selective laser melting

Graphene-reinforced AlSi10Mg matrix composites are high-strength materials with significant potential for applications involving high thermal and mechanical loads. The composite has a promising future in catering to the automobile and aerospace sectors due to its exceptional properties. Considering this, the current study explores the thermal, surface, and compressive properties of 0.1% graphene-reinforced AlSi10Mg composite fabricated using the selective laser melting process. The study examines the effect of process parameters, including laser power (200–400 W), layer thickness (30 and 60 μm), hatch spacing (50–90 μm), and graphene reinforcement, on compressive strength, surface properties, and thermal behavior. The results indicate that the increasing volumetric energy density improves the compressive strength and wettability properties, while also increasing surface roughness. Furthermore, wettability and compressive strength improve with the higher laser power, while surface roughness and wettability are at their lowest at 70 μm hatch spacing. The incorporation of graphene enhances the reaction temperature, thermal stability, and heat absorption, while also affecting the precipitation of the intermetallic compound of the composite.