Microstructure evolution and mechanical properties of selective laser melting fabricated hybrid particle reinforced AlSi10Mg composites

(SiC+TiB₂)/AlSi10Mg composite powders with 5 wt% micro-SiC particles and 1.5 wt% nano-TiB₂ particles were prepared by high energy ball milling, and hybrid particle reinforced aluminum matrix composites (AMCs) were fabricated by SLM. This study systematically investigated the effects of SiC and TiB₂ particles on the phase composition, microstructure evolution, grain crystallization, and mechanical properties. The machanisms of potential strengthening and fracture mechanisms were revealed. The tribological behaviors of the hybrid particle reinforced AlSi10Mg composites under different friction conditions were explored as well. The results show that the 1.5 wt% nano-TiB₂ particles provided sufficient nucleation sites for grain growth, completely transforming from coarse columnar to fined equiaxed grains. The average grain size decreases from 7.98 μm to 3.34 μm, and the texture is significantly weakened, which is beneficial to the homogenization of the microstructure, thereby improving the mechanical properties of the SiC/AlSi10Mg composites. The (SiC+TiB₂)/AlSi10Mg composites showed a high ultimate tensile strength (∼ 489.1 MP), hardness (172.2 HV) and elongation of 8.2 %. The enhancement of mechanical properties was attributed to Orowan strengthening, fine grain strengthening, and load-bearing strengthening. Due to the Si precipitates and fine microstructure, a low wear rate of 0.50 × 10⁻⁵ g/m was obtained, 10.7 % lower than that of SLM formed SiC/AlSi10Mg composites. The friction process is affected by abrasive wear, adhesive wear and delamination wear. It is aspired that the current approach can provide guidance for the design of new alloy systems with excellent performance.