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Paper | Open Access

Investigation of melt-growth alumina/aluminum titanate composite ceramics prepared by directed energy deposition

Yunfei Huang, Dongjiang Wu, Dake Zhao, Fangyong Niu( ), Guangyi Ma
Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian, Liaoning Province 116024, People's Republic of China
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Abstract

Al2O3/Al6Ti2O13 composite ceramics with low thermal expansion properties are promising for the rapid preparation of large-scale and complex components by directed energy deposition-laser based (DED-LB) technology. However, the wider application of DED-LB technology is limited due to the inadequate understanding of process conditions. The shaping quality, microstructure, and mechanical properties of Al2O3/Al6Ti2O13 (6 mol% TiO2) composite ceramics were systematically investigated as a function of energy input in an extensive process window. On this basis, the formation mechanism of solidification defects and the evolution process of microstructure were revealed, and the optimized process parameters were determined. Results show that high energy input improves the fluidity of the molten pool and promotes the uniform distribution and full growth of constituent phases, thus, facilitating the elimination of solidification defects, such as pores and strip gaps. In addition, the microstructure size is strongly dependent on the energy input, increasing when the energy input increases. Moreover, the morphology of the α-Al2O3 phase gradually transforms from cellular into cellular dendrite with increasing energy input due to changing solidification conditions. Under the comprehensive influence of solidification defects and microstructure size, the fracture toughness and flexural strength of Al2O3/Al6Ti2O13 composite ceramics present a parabolic law behavior as the energy input increases. Optimal shaping quality and excellent mechanical properties are achieved at an energy input range of 0.36−0.54 W*min2 g−1 mm−1. Within this process window, the average microhardness, fracture toughness, and flexural strength of Al2O3/Al6Ti2O13 composite ceramics are up to 1640 Hv, 3.87 MPa m1/2, and 227 MPa, respectively. This study provides practical guidance for determining the process parameters of DED-LB of melt growth Al2O3/Al6Ti2O13 composite ceramics.

Keywords

additive manufacturingAl2O3composite ceramicsmicrostructuremechanical properties

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International Journal of Extreme Manufacturing
Volume 3 Issue 3,
September 2021
Pages 035101-035101
DOI: 10.1088/2631-7990/abf71a
Cite this article:
Huang Y, Wu D, Zhao D, et al. Investigation of melt-growth alumina/aluminum titanate composite ceramics prepared by directed energy deposition. International Journal of Extreme Manufacturing, 2021, 3(3): 035101. https://doi.org/10.1088/2631-7990/abf71a

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Received: 12 November 2020
Revised: 02 January 2022
Accepted: 12 April 2021
Published: 03 May 2021
© 2021 The Author(s).

Original content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
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