Laser Powder Bed Fusion of Titanium‐Coated Diamond‐Reinforced Aluminum Matrix Composites

Diamond‐reinforced aluminum matrix composite (DAMC) presents superior thermal conductivity and strength/weight ratio. Laser powder bed fusion (L‐PBF) technology could offer new possibilities for these materials by enabling fabrication of parts with complex geometries and desired compositions. This article studies different diamond content (3 and 5 wt%) and diamond surface treating (titanium‐coated or uncoated) on the formation behavior of DAMC produced by L‐PBF. A comprehensive analysis is conducted to examine different defect generation mechanisms encountered during L‐PBF. Additionally, process parameters for DAMC with varying diamond contents are optimized. It indicates that the DAMC with 3 wt% titanium‐coated diamond achieves a high relative density of 99.0%. Better thermal conductivity and strength are obtained compared to the base material, AlSi10Mg alloys. The wear performance of the composites is evaluated using a ball‐on‐disk tribometer. It shows excellent wear resistance, with a reduction in wear rate by 94.8–96.2% compared to the base AlSi10Mg alloy.