Steel grid-reinforced aluminum matrix composite prepared via wire-based friction stir additive manufacturing

作者：Zeyu Zhang, Long Wan, Yuming Xie, Qi Wen, Sihao Chen, Yongxian Huang · 发表于：Virtual and Physical Prototyping · 年份：2025 · DOI：10.1080/17452759.2025.2451114 · 被引用次数：19 · 研究领域：Aluminum Alloys Composites Properties、Advanced Welding Techniques Analysis、Additive Manufacturing and 3D Printing Technologies

Grid-reinforced metal matrix composites featuring tailorable mechanical properties pose significant challenges to additive manufacturing due to its co-controlling reinforcement structure and interfacial formation issues. Here, a dense steel grid-reinforced aluminum matrix composite was successfully prepared by wire-based friction stir additive manufacturing. No internal defects, like porosity, grid breakage, or interface cracking, were detected, and the reinforcing grids kept a predefined orientation without deviation. A strong interfacial bonding between the deposited layers and the grid was achieved due to sufficient matrix material flow and diffusion behaviour induced by severe plastic deformation. Compared to pure aluminum, the ultimate tensile strength and flexural strength of the as-deposited composite increased by 27.1% and 41.8%, without loss of ductility, by incorporating a 12.3 vt.% of the steel grid. This work provides an efficient approach to fabricating large-scale metal matrix composites reinforced with other high-performance continuous grid, such as metal fibre and carbon fibre grid.