Synthesis of an Ultra-high Hardness Nanostructured AlSi10Mg Alloy via A Hybrid Laser Powder Bed Fusion/High-Pressure Torsion Approach

The hybrid combination of laser powder bed fusion (L-PBF) and high-pressure torsion, respectively an additive manufacturing (AM) and severe plastic deformation (SPD) has recently emerged as an important field of study due to the ability to produce novel nanostructured metals/alloys with simultaneous enhancements in mechanical (hardness, yield and tensile strengths) and functional (corrosion and wear) performances. Pioneering studies on the hybrid L-PBF/HPT approach was focused on 316L stainless steel (316L SS) and AlCuMg alloys due to their widespread engineering applications. AlSi10Mg, an alloy widely used in the automotive industry is expected to benefit from this hybrid combination but has not been investigated before. Thus, this study aims to investigate the microstructural features and hardness of the nanostructured AlSi10Mg attained by the hybrid L-PBF/HPT technique via transmission electron microscopy (TEM) and Vickers microhardness (HV) measurements, respectively. The results showed novel microstructures, including nano-scale grain sizes (< 200 nm), nano-sized Mg2Si precipitates (~200 nm), and dense dislocation networks. The average hardness value was determined as 230 ± 20 HV, homogeneously distributed throughout the disk surface as indicated by the low deviation (error bar). The microstructures of L-PBF/HPT-synthesised AlSi10Mg are different and significantly refined than conventionally cast AlSi10Mg, which contributed to the two- to four-fold hardness (typical HV values of as-cast AlSi10Mg ranges from 60 – 68 HV) increase via grain boundary and dislocation strengthening mechanisms.