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Melt-grown alumina-based composites are receiving increasing attention due to their potential for aerospace applications; however, the rapid preparation of high-performance components remains a challenge. Herein, a novel route for 3D printing dense (< 99.4%) high-performance melt-grown alumina-mullite/glass composites using directed laser deposition (DLD) is proposed. Key issues on the composites, including phase composition, microstructure formation/evolution, densification, and mechanical properties, are systematically investigated. The toughening and strengthening mechanisms are analyzed using classical fracture mechanics, Griffith strength theory, and solid/glass interface infiltration theory. It is demonstrated that the composites are composed of corundum, mullite, and glass, or corundum and glass. With the increase of alumina content in the initial powder, corundum grains gradually evolve from near-equiaxed dendrite to columnar dendrite and cellular structures due to the weakening of constitutional undercooling and small nucleation undercooling. The microhardness and fracture toughness are the highest at 92.5 mol% alumina, with 18.39±0.38 GPa and 3.07±0.13 MPa·m1/2, respectively. The maximum strength is 310.1±36.5 MPa at 95 mol% alumina. Strength enhancement is attributed to the improved densification due to the trace silica doping and the relief of residual stresses. The method unravels the potential of preparing dense high-performance melt-grown alumina-based composites by the DLD technology.


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Microstructure and mechanical properties of melt-grown alumina-mullite/glass composites fabricated by directed laser deposition

Show Author's information Dake ZHAODongjiang WUJing SHIFangyong NIU( )Guangyi MA
Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian 116024, China

Abstract

Melt-grown alumina-based composites are receiving increasing attention due to their potential for aerospace applications; however, the rapid preparation of high-performance components remains a challenge. Herein, a novel route for 3D printing dense (< 99.4%) high-performance melt-grown alumina-mullite/glass composites using directed laser deposition (DLD) is proposed. Key issues on the composites, including phase composition, microstructure formation/evolution, densification, and mechanical properties, are systematically investigated. The toughening and strengthening mechanisms are analyzed using classical fracture mechanics, Griffith strength theory, and solid/glass interface infiltration theory. It is demonstrated that the composites are composed of corundum, mullite, and glass, or corundum and glass. With the increase of alumina content in the initial powder, corundum grains gradually evolve from near-equiaxed dendrite to columnar dendrite and cellular structures due to the weakening of constitutional undercooling and small nucleation undercooling. The microhardness and fracture toughness are the highest at 92.5 mol% alumina, with 18.39±0.38 GPa and 3.07±0.13 MPa·m1/2, respectively. The maximum strength is 310.1±36.5 MPa at 95 mol% alumina. Strength enhancement is attributed to the improved densification due to the trace silica doping and the relief of residual stresses. The method unravels the potential of preparing dense high-performance melt-grown alumina-based composites by the DLD technology.

Keywords:

laser, additive manufacturing, alumina, mullite, microstructure, mechanical properties
Received: 07 February 2021 Revised: 19 June 2021 Accepted: 08 July 2021 Published: 12 November 2021 Issue date: January 2022
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Publication history

Received: 07 February 2021
Revised: 19 June 2021
Accepted: 08 July 2021
Published: 12 November 2021
Issue date: January 2022

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© The Author(s) 2021.

Acknowledgements

This work was supported by the National Natural Science Foundation of China (51805070 and 51790172), the Natural Science Foundation of Liaoning Province (2019-ZD-0010, 2020-BS-057), and the Basic Scientific Research Program for the Central Universities (DUT19RC (3) 060).

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