Skip to main content
SpringerLink
Log in

Effect of Fe2O3 content on microstructure of Al powder consolidated parts via selective laser melting using various laser powers and speeds

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In situ constituents were formed inside an aluminium matrix via selective laser melting (SLM) of Al powder mixed with 5, 10, and 15 wt% Fe2O3 powder (using various laser powers and speeds), in order to investigate the effect of Fe2O3 content on the microstructural characteristics of novel aluminium matrix composites. The unique microstructures such as coralline-like Al–Fe intermetallics were formed by the in situ reaction, being Fe3Al at first but Al13Fe4 soon after that. These coralline-like intermetallics were fragmented (under appropriate laser parameters and/or higher Fe2O3 contents) and mixed up with Al oxide particles, reinforcing the matrix. The higher Fe2O3 increased the formation of other combinations such as Al2Fe, AlFe, and Fe3Al as well as metastable Al oxides in addition to equilibrium Al13Fe4 (Al3Fe) and stable α-Al2O3. A very fine, well-bonded, and homogeneous distribution of hard particles was achieved in high Fe2O3 contents, efficiently increasing the hardness and providing an advanced Al matrix composite.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Wu JM, Li ZZ (2000) Nanostructured composite obtained by mechanically driven reduction reaction of CuO and Al powder mixture. J Alloys Compd 299:9–16

    Article  Google Scholar 

  2. Yu P, Deng C-J, Ma N-G, Ng DHL (2004) A new method of producing uniformly distributed alumina particles in Al-based metal matrix composite. Mater Lett 58(5):679–682

    Article  Google Scholar 

  3. Fan T, Zhang D, Yang G, Shibayanagi T, Naka M (2003) Fabrication of in situ Al2O3/Al composite via remelting. J Mater Process Technol 142:556–561

    Article  Google Scholar 

  4. Lu L, Lai MO, Chen FL (1997) Al-4 wt% Cu composite reinforced with in-situ TiB2 particles. Acta Mater 45:4297–4309

    Article  Google Scholar 

  5. Tjong SC, Wang GS, Geng L, Mai YW (2004) Cyclic deformation behavior of in situ aluminum-matrix composites of the system Al-Al3Ti-TiB2-Al2O3. Compos Sci Technol 64:1971–1980

    Article  Google Scholar 

  6. Tong XC, Fang HS (1998) Al-TiC composites in situ-processed by ingot metallurgy and rapid solidification technology: Part II. Mechanical behavior. Metall Mater Trans A 29:893–902

    Article  Google Scholar 

  7. Hsu CJ, Chang CY, Kao PW, Ho NJ, Chang CP (2006) Al-Al3Ti nanocomposites produced in situ by friction stir processing. Acta Mater 54:5241–5249

    Article  Google Scholar 

  8. Maity PC, Chakraborty PN, Panigrahi SC (1997) Al-Al2O3 in situ particle composites by reaction of CuO particles in molten pure Al. Mater Lett 30:147–151

    Article  Google Scholar 

  9. Yu P, Deng C-J, Ma N-G, Yau M-Y, Ng DHL (2003) Formation of nanostructured eutectic network in [alpha]-Al2O3 reinforced Al-Cu alloy matrix composite. Acta Mater 51:3445–3454

    Article  Google Scholar 

  10. Fan R-H, Lü H-L, Sun K-N, Wang W-X, Yi X-B (2006) Kinetics of thermite reaction in Al-Fe2O3 system. Thermochim Acta 440:129–131

    Article  Google Scholar 

  11. Yang J, La P, Liu W, Hao Y (2004) Microstructure and properties of Fe3Al-Fe3AlC0.5 composites prepared by self-propagating high temperature synthesis casting. Mater Sci Eng A 382:8–14

    Article  Google Scholar 

  12. Durães L, Costa BFO, Santos R, Correia A, Campos J, Portugal A (2007) Fe2O3/aluminum thermite reaction intermediate and final products characterization. Mater Sci Eng A 465:199–210

    Article  Google Scholar 

  13. Louvis E, Fox P, Sutcliffe CJ (2011) Selective laser melting of aluminium components. J Mater Process Technol 211:275–284

    Article  Google Scholar 

  14. Buchbinder D, Schleifenbaum H, Heidrich S, Meiners W, Bültmann J (2011) High power selective laser melting (HP SLM) of aluminum parts. Phys Procedia 12A:271–278

    Article  Google Scholar 

  15. Dadbakhsh S, Hao L (2012) In situ formation of particle reinforced Al matrix composite by selective laser melting of Al/Fe2O3 powder mixture. Adv Eng Mater 14:45–48

    Article  Google Scholar 

  16. Dadbakhsh S, Hao L, Jerrard PGE, Zhang DZ (2012) Experimental investigation on selective laser melting behaviour and processing windows of in situ reacted Al/Fe2O3 powder mixture. Powder Technol 231:112–121

    Article  Google Scholar 

  17. Dadbakhsh S, Hao L (2014) Effect of layer thickness in selective laser melting on microstructure of Al/5wt.%Fe2O3 powder consolidated parts. Sci World J 2014:1–10

    Article  Google Scholar 

  18. Griger Á, Stefániay V (1996) Equilibrium and non-equilibrium intermetallic phases in Al-Fe and Al-Fe-Si alloys. J Mater Sci 31:6645–6652

    Article  Google Scholar 

  19. Levin I, Brandon D (1998) Metastable alumina polymorphs: crystal structures and transition sequences. J Am Ceram Soc 81:1995–2012

    Article  Google Scholar 

  20. Zhang K, Chen GN (2000) Effect of SiC particles on crystal growth of Al-Si alloy during laser rapid solidification. Mater Sci Eng A 292:229–231

    Article  Google Scholar 

  21. Mei J, Halldearn RD, Xiao P (1999) Mechanisms of the aluminium-iron oxide thermite reaction. Scr Mater 41:541–548

    Article  Google Scholar 

  22. Allen CM, O’Reilly KAQ, Cantor B (2001) Effect of semisolid microstructure on solidified phase content in 1xxx Al alloys. Acta Mater 49:1549–1563

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. College of Engineering, Mathematics and Physical Sciences, University of Exeter, Exeter, UK

    S. Dadbakhsh & L. Hao

  2. PMA, Department of Mechanical Engineering, KU Leuven, 3001, Leuven, Belgium

    S. Dadbakhsh

Authors
  1. S. Dadbakhsh
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. L. Hao
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to S. Dadbakhsh.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Dadbakhsh, S., Hao, L. Effect of Fe2O3 content on microstructure of Al powder consolidated parts via selective laser melting using various laser powers and speeds. Int J Adv Manuf Technol 73, 1453–1463 (2014). https://doi.org/10.1007/s00170-014-5915-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-014-5915-3

Keywords

Search

Navigation