A High-Strength TiB2-Modified Al-Si-Mg-Zr Alloy Fabricated by Laser Powder-Bed Fusion

doi:10.1007/s40195-025-01825-1

Abstract

Abstract:

To increase the strength of the laser powder-bed fusion (LPBF) Al-Si-based aluminum alloy, TiB₂ ceramic particles were selected to be mixed with high-Mg content Al-Si-Mg-Zr powder, and then a novel TiB₂/Al-Si-Mg-Zr composite was fabricated using LPBF. The results indicated that a dense sample with a maximum relative density of 99.85% could be obtained by adjusting the LPBF process parameters. Incorporating TiB₂ nanoparticles enhanced the powder's laser absorption rate, thereby raising the alloy's intrinsic heat treatment temperature and consequently facilitating the precipitation of Si and βʺ nanoparticles in the α-Al cells. Moreover, the rapid cooling process during LPBF resulted in numerous alloying elements with low-stacking fault energy dissolving in the α-Al matrix, thus promoting the formation of the 9R phase. After a 48 h direct aging treatment at 150 °C, the strength of the alloy slightly increased due to the increase of nanoprecipitates. Both yield strength and ultimate tensile strength of the LPBF TiB₂/Al-Si-Mg-Zr alloy were significantly higher than that of other LPBF TiB₂-modified aluminum alloys with external addition.

Key words: Laser powder-bed fusion, Aluminum alloy, TiB2 ceramic particle, 9R phase, Mechanical properties

Yaoxiang Geng, Keying Lv, Chunfeng Zai, Zhijie Zhang, Anil Kunwar. A High-Strength TiB₂-Modified Al-Si-Mg-Zr Alloy Fabricated by Laser Powder-Bed Fusion[J]. Acta Metallurgica Sinica (English Letters), 2025, 38(4): 542-554.

Figures/Tables 16

Table 1 Chemical composition of the Al-Si-Mg-Zr powder (wt%)

Powder	Chemical composition
Powder	Si	Mg	Zr	Fe	Al
Al-Si-Mg-Zr	7.43	1.57	0.37	0.08	Bal.

Fig. 1 a SEM surface morphology, b-f corresponding EDS mappings of the TiB2/Al-Si-Mg-Zr composite powder

Table 2 LPBF process parameters of the specimens

Laser power (W)	Laser beam diameter (μm)	Powder layer thickness (μm)	Hatch spacing (μm)	Laser scanning speed (mm/s)	Angle of rotation (°)
250, 350	100	30	100	800, 900, 1000, 1100, 1200	67

Fig. 2 a Schematic of the scanning strategy, b morphology of the LPBF TiB2/Al-Si-Mg-Zr composite specimens

Fig. 3 Change of a relative density, b VED of the TiB2/Al-Si-Mg-Zr composite fabricated under different process parameters

Fig. 4 a, d SEM and b, e LSCM upper surface topography, c, f OM images of the TiB2/Al-Si-Mg-Zr alloy fabricated at various process parameters

Fig. 5 a, b EBSD orientation maps obtained from a parallel and b perpendicular to the building directions, and c low, d high magnification (originated from the fine region) SEM images of the LPBF TiB2/Al-Si-Mg-Zr samples obtained from parallel to the building direction

Fig. 6 a SEM image and b-f corresponding EDS mapping of the LPBF TiB2/Al-Si-Mg-Zr alloy, b Al, c Si, d Mg, e Zr, f Ti

Fig. 7 a TEM-BF image and b-f corresponding EDS mappings of the LPBF TiB2/Al-Si-Mg-Zr alloy, b Si, c Mg, d Zr, e Ti, f Fe

Fig. 8 a, b High-resolution TEM images, and c inverse FFT obtained from the FFT of the inset in b. FFT image originated from a indicated the presence of βʺ phase. Inverse FFT analysis revealed that the 9R structure consists of three Shockley partials. When viewed along the [110] direction, the stacking sequence of the 9R phase is observed to follow the …ABC/BCA/CAB/…

Fig. 9 SEM images of the LPBF TiB2/Al-Si-Mg-Zr samples after aging at a 150 °C, b 200 °C, c 250 °C, d 300 °C, e 400 °C, f 500 °C for 2 h

Fig. 10 SEM images of the LPBF TiB2/Al-Si-Mg-Zr samples after aging at 150 °C for a 4 h, b 12 h, c 24 h, d 48 h

Fig. 11 Variations of Vickers hardness of the LPBF TiB2/Al-Si-Mg-Zr samples after aging a at different temperatures for 2 h, b at 150 °C for different time

Fig. 12 a Tensile stress-strain curves, and comparison of the b YS, c UTS of the LPBF TiB2/Al-Si-Mg-Zr samples with other previously reported external addition TiB2-modified aluminum alloys fabricated using LPBF

Table 3 Mechanical properties of as-built and aging LPBF TiB2/Al-Si-Mg-Zr and Al-Si-Mg-Zr samples

Samples	Condition	YS (MPa)	UTS (MPa)	Elongation (%)
TiB₂/Al-Si-Mg-Zr	As-built	408 ± 9	514 ± 8	4.7 ± 1.2
	150 °C-12 h	406 ± 10	518 ± 6	4.8 ± 1.1
	150 °C-24 h	403 ± 11	520 ± 12	4.7 ± 1.1
	150 °C-48 h	419 ± 3	517 ± 10	4.4 ± 1.2
	250 °C-2 h	221 ± 10	345 ± 7	8.3 ± 0.7
	300 °C-2 h	182 ± 1	279 ± 1	13.5 ± 4
Al-Si-Mg-Zr	As-built	343 ± 3	485 ± 4	10.2 ± 0.2
	300 °C-2 h	198 ± 1	305 ± 6	28.3 ± 3.3

Fig. 13 SEM low- and high-magnification fracture morphology images of the LPBF TiB2/Al-Si-Mg-Zr samples at different heat treatment conditions, a1, a2 as-built, b1, b2 150 °C-24 h, c1, c2 300 °C-2 h

References 52

[1]	N.T. Aboulkhair, M. Simonelli, L. Parry, I. Ashcroft, C. Tuck, R. Hague, Prog. Mater. Sci. 106, 100578 (2019).
[2]	Y.X. Geng, H. Tang, J.H. Xu, Y.X. Wang, Z. He, Z.J. Zhang, H.B. Ju, L.H. Yu, Int. J. Min. Metall. Mater. 29, 1770 (2022).
[3]	Y. Lai, Y. Deng, X.W. Zhu, Y.F. Guo, G.F. Xu, J.W. Huang, Z.M. Yin, Trans. Nonferrous Met. Soc. China 33, 357 (2023).
[4]	A. Du Plessis, C. Broeckhoven, I. Yadroitsava, I. Yadroitsev, C.H. Hands, R. Kunju, D. Bhate, Addit. Manuf. 27, 408 (2019). DOI
[5]	J. Yu, Y.X. Geng, Y.K. Chen, X. Wang, Z.J. Zhang, H. Tang, J.H. Xu, H.B. Ju, D.P. Wang, Int. J. Min. Metall. Mater. 31, 2221 (2024).
[6]	J. Yu, Y.X. Geng, H.B. Ju, Z.J. Zhang, J.H. Xu, Trans. Nonferrous Met. Soc. China 34, 2431 (2024).
[7]	L. Zhao, L.B. Song, J.G.S. Macías, Y.X. Zhu, M.S. Huang, A. Simar, Z.H. Li, Addit. Manuf. 56, 102914 (2022).
[8]	X.P. Li, G. Ji, Z. Chen, A. Addad, Y. Wu, H.W. Wang, J. Vleugels, J. Van Humbeeck, J.P. Kruth, Acta Mater. 129, 183 (2017).
[9]	Z. Feng, H. Tan, Y.B. Fang, X. Lin, W.D. Huang, J. Mater. Process. Technol. 299, 117386 (2022).
[10]	L.X. Xi, D.D. Gu, S. Guo, R.Q. Wang, K. Ding, K.G. Prashanth, J. Mater. Res. Technol. 9, 2611 (2020).
[11]	Z.G. Zhu, Z.H. Hu, H. Li Seet, T.T. Liu, W.H. Liao, U. Ramamurty, S.M.L. Nai, Int. J. Mach. Tool Manuf. 190, 104047 (2023).
[12]	W.H. Yu, S.L. Sing, C.K. Chua, C.N. Kuo, X.L. Tian, Prog. Mater. Sci. 104, 330 (2019). DOI
[13]	Y.X. Geng, Q. Wang, Y.M. Wang, Q.H. Zang, S.B. Mi, J.H. Xu, Y.K. Xiao, Y. Wu, J.H. Luan, Mater. Des. 218, 110674 (2022).
[14]	Y.X. Geng, Y.M. Wang, J.H. Xu, S.B. Mi, S.M. Fan, Y.K. Xiao, Y. Wu, J.H. Luan, J. Alloys Compd. 867, 159103 (2021).
[15]	Y.X. Geng, C.F. Zai, J. Yu, H. Tang, H.W. Lv, Z.J. Zhang, Trans. Nonferrous Met. Soc. China 34, 2733 (2024).
[16]	J.F. Qi, C.Y. Liu, Z.W. Chen, Z.Y. Liu, J.S. Tian, J. Feng, I.V. Okulov, J. Eckert, P. Wang, Mater. Sci. Eng. A 855, 143833 (2022).
[17]	J. Ciurana, L. Hernandez, J. Delgado, Int. J. Adv. Manuf. Technol. 68, 1103 (2013).
[18]	J.R. Guan, Q.P. Wang, Materials 16, 2757 (2023).
[19]	M. Simonelli, C. Tuck, N.T. Aboulkhair, I. Maskery, I. Ashcroft, R.D. Wildman, R. Hague, Metall. Mater. Trans. A 46, 3842 (2015).
[20]	Y.L. Li, D.D. Gu, Mater. Des. 63, 856 (2014).
[21]	I. Maskery, N.T. Aboulkhair, M.R. Corfield, C. Tuck, A.T. Clare, R.K. Leach, R.D. Wildman, I.A. Ashcroft, Mater. Charact. 111, 193 (2016).
[22]	N.T. Aboulkhair, N.M. Everitt, I. Ashcroft, C. Tuck, Addit. Manuf. 1-4, 77 (2014).
[23]	H.L. Huang, W. Li, C.B. Hu, L.P. Ding, Z.H. Jia, N. Zhou, Mater. Sci. Eng. A 836, 142570 (2022).
[24]	L. Zhou, H. Hyer, S. Park, H. Pan, Y.L. Bai, K.P. Rice, Y. Sohn, Addit. Manuf. 28, 485 (2019). DOI
[25]	H. Tang, Y.X. Geng, S.N. Bian, J.H. Xu, Z.J. Zhang, Acta Metall. Sin.-Engl. Lett. 35, 466 (2022).
[26]	S.Y. Ahn, J. Moon, Y.T. Choi, E.S. Kim, S.G. Jeong, J.M. Park, M. Kang, H. Joo, H.S. Kim, Mater. Sci. Eng. A 844, 143164 (2022).
[27]	J. Wan, K.A. Li, H.R. Geng, B. Chen, J.H. Shen, Y.Z. Guo, K. Kondoh, A. Bahador, J.S. Li, Mater. Res. Lett. 11, 422 (2023).
[28]	N. Tabatabaei, A. Zarei-Hanzaki, A. Moshiri, H.R. Abedi, J. Mater. Res. Technol. 23, 6039 (2023).
[29]	W. Cheng, Y.Z. Liu, X.J. Xiao, B. Huang, Z.G. Zhou, X.H. Liu, Mater. Sci. Eng. A 834, 142435 (2022).
[30]	S.H. Wang, Y. Wang, Y.J. Zhang, F. Wang, T. Hashimoto, X.R. Zhou, Z.Y. Fan, Q. Ramasse, Scr. Mater. 253, 116310 (2024).
[31]	Y.J. Ren, B. Han, H. Wu, J.C. Wang, B. Liu, B.Q. Wei, Z.B. Jiao, I. Baker, Scr. Mater. 224, 115115 (2023).
[32]	T.C. Schulthess, P.E.A. Turchi, A. Gonis, Acta Mater. 46, 2215 (1998).
[33]	N.A. Richter, Y.F. Zhang, D.Y. Xie, R. Su, Q. Li, S. Xue, T. Niu, J. Wang, H. Wang, X. Zhang, Mater. Res. Lett. 9, 91 (2021). DOI
[34]	Y.X. Geng, X. Wang, Y.K. Chen, Z.F. Shan, Z.J. Zhang, A. Kunwar, Virtual Phys. Prototyp. 19, 2416518 (2024).
[35]	Q. Li, S.C. Xue, J. Wang, S. Shao, A.H. Kwong, A. Giwa, Z. Fan, Y. Liu, Z.M. Qi, J. Ding, H. Wang, J.R. Greer, H.Y. Wang, X.H. Zhang, Adv. Mater. 30, 1704629 (2018).
[36]	J.F. Zhang, D.S. Zhou, X.Y. Pang, B.W. Zhang, Y. Li, B.H. Sun, R.Z. Valiev, D.L. Zhang, Acta Mater. 244, 118540 (2023).
[37]	F.C. An, J.H. Hou, B.N. Qian, C.H. Liebscher, W.J. Lu, Mater. Charact. 202, 112993 (2023).
[38]	K.V. Yang, P. Rometsch, C.H.J. Davies, A. Huang, X. Wu, Mater. Des. 154, 275 (2018).
[39]	T. Kimura, T. Nakamoto, Mater. Des. 89, 1294 (2016).
[40]	Y.N. Meng, Z.Y. Yu, P. Rong, G.J. Li, J. Laser Appl. 32, 022007 (2020).
[41]	L.X. Xi, D.D. Gu, K.J. Lin, S. Guo, Y. Liu, Y.X. Li, M. Guo, J. Mater. Res. 35, 559 (2020).
[42]	Y.X. Li, D.D. Gu, H. Zhang, L.X. Xi, Chin. J. Mech. Eng. 33, 33 (2020).
[43]	R.Q. Wang, L.X. Xi, K. Ding, B. Gökce, S. Barcikowski, D.D. Gu, Adv. Powder Technol. 33, 103687 (2022).
[44]	Q.Z. Wang, X. Lin, N. Kang, X.L. Wen, Y. Cao, J.L. Lu, D.J. Peng, J. Bai, Y.X. Zhou, M. El Mansori, W.D. Huang, Mater. Sci. Eng. A 840, 142950 (2022).
[45]	C. Gao, Z. Liu, Z. Xiao, W. Zhang, K. Wong, A.H. Akbarzadeh, J. Alloys Compd. 853, 156722 (2021).
[46]	Y.J. Shi, K. Yang, S.K. Kairy, F. Palm, X.H. Wu, P.A. Rometsch, Mater. Sci. Eng. A 732, 41 (2018).
[47]	R. Xu, R.D. Li, T.C. Yuan, H.B. Zhu, M.B. Wang, J.F. Li, W. Zhang, P. Cao, Mater. Sci. Eng. A 859, 144181 (2022).
[48]	Q. Wang, Z. Li, S.J. Pang, X.N. Li, C. Dong, P.K. Liao, Entropy 20, 878 (2018).
[49]	R.D. Li, M.B. Wang, Z.M. Li, P. Cao, T.C. Yuan, H.B. Zhu, Acta Mater. 193, 83 (2020).
[50]	D. Bufford, Y. Liu, J. Wang, H. Wang, X. Zhang, Nat. Commun. 5, 4864 (2014). DOI PMID
[51]	D.K. Kim, W. Woo, J.H. Hwang, K.E. An, S.H. Choi, J. Alloys Compd. 686, 281 (2016).
[52]	L. Zhao, J.G.S. Macías, L. Ding, H. Idrissi, A. Simar, Mater. Sci. Eng. A 764, 138210 (2019).

A High-Strength TiB₂-Modified Al-Si-Mg-Zr Alloy Fabricated by Laser Powder-Bed Fusion

RichHTML

PDF (PC)

Knowledge

Abstract

Cite this article

share this article

Figures/Tables 16

References 52

Related Articles 15

Recommended Articles

Metrics

Comments

[1]	Haijian Liu, Tianle Li, Xifeng Li, Huiping Wu, Zhiqiang Wang, Jun Chen. Strength Optimization of Diffusion-Bonded Ti₂AlNb Alloy by Post-Heat Treatment [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(4): 614-626.
[2]	X. W. Shang, Z. G. Lu, R. P. Guo, L. Xu. Influence of Hot Isostatic Pressing Temperature on Microstructure and Mechanical Properties of Ti-6.5Al-3.5Mo-1.5Zr-0.3Si Alloy [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(4): 627-641.
[3]	Jing Wang, Xuejian Wang, Zongning Chen, Huijun Kang, Tongmin Wang, Enyu Guo. In Vitro Corrosion Behavior and Mechanical Property of Novel Mg-Sn-In-Ga Alloys for Orthopedic Applications [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(3): 353-366.
[4]	Xiaotong Lu, Pingyun Yuan, Zhengquan Wang, Xiaocheng Li, Hanyuan Liu, Wenhao Zhou, Kun Sun, Yongliang Mu. Mechanical Properties and Corrosion Behavior of Porous Zn Alloy as Biodegradable Materials [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(3): 367-382.
[5]	Nafiseh Mollaei, Seyed Mahmood Fatemi, Mohammad Reza Aboutalebi, Seyed Hossein Razavi, Wiktor Bednarczyk. Microstructure, Texture, Mechanical Properties, and Corrosion Behavior of Biodegradable Zn-0.2Mg Alloy Processed by Multi-Directional Forging [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(3): 507-525.
[6]	Jian Dong, Jufu Jiang, Ying Wang, Minjie Huang, Jingbo Cui, Tao Song. Effect of Solution and Aging Treatment on Microstructure and Mechanical Properties of Al-14Si-5Cu-1.1Mg-2.3Ni-0.3La Alloy [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(3): 449-464.
[7]	Chenghao Liu, Wenchao Dong, Jian Sun, Shanping Lu. Effect of Precipitation Behavior and Deformation Twinning Evolution on the Mechanical Properties of 16Cr-25.5Ni-4.2Mo Superaustenitic Stainless Steel Weld Metals [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(2): 338-352.
[8]	Sai Chen, Shuangjie Chu, Bo Mao. Iron-Based Metal Matrix Composite: A Critical Review on the Microstructural Design, Fabrication Processes, and Mechanical Properties [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(1): 1-44.
[9]	Zheng Liu, De-Chun Ren, Lian-Min Zhang, Ai-Li Ma, Hai-Bin Ji, Yu-Gui Zheng. Synergistic Improvement in Ductility and Hot Nitric Acid Corrosion Resistance of LPBF Ti-6Al-4V Alloy via Hot Isostatic Pressing [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(1): 102-106.
[10]	Qishan Sun, Shitong Wei, Shanping Lu. Coupling Effect Mechanism of the δ-Ferrite and M₂₃C₆ on the Mechanical Properties of 9Cr-Steel Deposited Metals [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(1): 121-138.
[11]	Ye Liu, Shuran Chu, Hui Guo, Mengyao Kong, Chenxi Liu, Jingwen Zhang, Ran Ding, Yongchang Liu. Enhancing the Strength of Medium Mn Steel by Flash Treatment [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(1): 139-150.
[12]	Hongwei Yan, Yong’an Zhang, Wei Xiao, Boyu Xue, Rui Liu, Xiwu Li, Zhihui Li, Baiqing Xiong. Experimental and DFT Investigations of AlNbTiVZr High Entropy Alloys with Excellent Mechanical Properties [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(9): 1480-1490.
[13]	Zirui Chen, Liyuan Wang, Jiayu Zhao, Guanhua Cui, Zhuo Gao, Zhiyuan Fan, Xiaohui Shi, Junwei Qiao. Microstructure and Mechanical Properties of the Ti₆₂Nb₁₂Mo₁₂Ta₁₂W₂ Refractory High Entropy Alloy Prepared through Spark Plasma Sintering [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(8): 1387-1398.
[14]	Shasha Qu, Yingju Li, Bingyu Lu, Cuiping Wang, Yuansheng Yang. Effects of Boron Addition on the Microstructure and Mechanical Properties of γ′-Strengthened Directionally Solidified CoNi-Base Superalloy [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(8): 1438-1452.
[15]	Guan-Cheng Gu, Zhao-Jing Han, Ze-Yu Chen, Zhao-Xuan Li, Sheng-Bao Xia, Zheng-Ning Li, Hua Jin, Wei-Wei Xu, Xing-Jun Liu. Theoretical Exploration of Alloying Effects on Stabilities and Mechanical Properties of γʹ Phase in Novel Co-Al-Nb-Base Superalloys [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(7): 1238-1248.