Laser Powder Bed Fusion of AlSi10Mg/W₂B₅ Composite: Powder Preparation, Phase Transformations, and Mechanical Properties

Metal matrix composites based on an aluminum (Al‐MMC) with W 2 B 5 particles are prepared by the laser powder bed fusion (LPBF) method. The feedstock material is obtained by pretreatment of the AlSi10Mg alloy with the W 2 B 5 functional additive in a planetary ball mill under conditions that ensured the preservation of the good flowability of the resulting powder and the distribution of ceramic particles on its surface. The resulting powders have a composite structure and are suitable for subsequent 3D printing. As a result of the optimization of the LPBF process parameters, dense Al‐MMC with 5, 10, and 15 wt% of W 2 B 5 is obtained for the first time. Microstructure investigations supported by X‐Ray phase diffraction reveal the presence of the WB phase as well as initial W 2 B 5 particles and the AlSi10Mg matrix in the resulting materials. The thermodynamic calculations support the observed formation of the WB phase due to the W 2 B 5 decomposition under the influence of the LPBF process conditions. All fabricated samples exhibit a high level of mechanical properties. A sample with 10 wt% of W 2 B 5 demonstrates the highest values of ultimate tensile strength and elongation (394.9 ± 3.1 MPa and 4.8% ± 0.5%, respectively) among the investigated composites.