Processability of A6061 Aluminum Alloy Using Laser Powder Bed Fusion by In Situ Synthesis of Grain Refiners

Despite the increasing interest in laser powder bed fusion (LPBF), only a few cast aluminum alloys are available for this process. This study focuses on improving LPBF processability of A6061 alloy, which is challenging due to its wide solidification range, dendritic columnar grain growth, and consequent cracking. To address these issues, situ-synthesized refiners can be used induce equiaxial growth prevent crack formation. RAM2 powder—a mixture A6061, Ti, B4C—was characterized processed using low-power machine create an situ particle-reinforced metal matrix composite. Parameter optimization was performed evaluate effect their variation printability alloy. Microstructural characterization samples revealed that complete reaction synthesis ceramic reinforcement did not occur. However, TiAl3 synthesized during process promoted partial refinement, leading formation grains preventing cracks. The tensile tests carried out optimized exhibit superior mechanical properties compared those through LPBF.