INFLUENCE OF SiC REINFORCEMENT ON MECHANICAL AND THERMAL PROPERTIES OF DMLS MANUFACTURED AlSi10Mg COMPOSITES

This study investigates the effect of 10% Silicon Carbide (SiC) reinforcement on the mechanical and thermal properties of AlSi10Mg made by Direct Metal Laser Sintering (DMLS). The research optimised laser energy density to study the effect on density, hardness, surface roughness, tensile strength and thermal behaviour. A comparison between unreinforced AlSi10Mg and SiC reinforced AlSi10Mg shows the complex interactions between laser processing parameters, thermal conductivity and phase stability. The introduction of SiC changes the material’s response to laser energy, affecting melt pool dynamics, solidification behaviour and residual stress formation. The results show SiC reinforcement improves hardness and wear resistance but increases thermal stresses, so process control is required to avoid defects like porosity, microcracking and SiC decomposition. The composite also has a change in optimal process parameters due to thermal conductivity, laser absorption and powder bed packing density compared to base alloy. These results highlight the need to balance laser power, scan speed and hatch spacing to get defect free structure with desired mechanical and thermal properties. This study provides insights into the role of SiC in Metal Matrix Composites (MMCs) and practical guidelines to refine DMLS parameters to get the best combination of strength, hardness, ductility and thermal stability in SiC reinforced AlSi10Mg parts. The results contribute to the understanding of MMCs for high performance applications in aerospace, automotive and thermal management systems.