Investigation on the scale-dependent behavior of microstructure characteristics of laser powder bed fused TiB₂/AlSi10Mg composite

The pre-alloyed TiB₂/AlSi10Mg composite, a new high-strength aluminum alloy developed for laser powder bed fusion (LPBF) technology, offers promising applications in lightweight and multi-scaled structures. However, thermal behavior during LPBF is markedly scale-dependent, leading to microstructural variations that significantly affect the load-bearing capacity of multi-scaled structures. Therefore, this study systematically investigates the scale-dependent behavior of microstructure characteristics of this composite. Utilizing a hatching scanning strategy, it was found that the marginal zones of samples are predominantly composed of coarse Al cell and Al grain structures, contrasting with the fine microstructures in the central zones. With increasing structure scale, cell and grain structures in both the marginal and central zones become more refined, with cell sizes reducing by 49 %–72 % (∼3.02 μm → 0.86–1.55 μm). Particularly, the minimum-scaled structures also feature broken eutectic Si particles and nanopores. The essence is primarily due to the low heat dissipation with higher peak temperature and longer duration time at high temperatures in both the small-scale structures and marginal zones. Additionally, smaller structures correlate with reduced microhardness and tensile strength, accompanied by the “softening” of the marginal zones. The strength of the minimum-scaled structure is only half that of the standard sample. Our findings suggest a scale threshold of 2.0 mm for researching scale effect. Encouragingly, incorporating additional contour scanning significantly counteracts the adverse influence of the scale effect. Owing to the combined influence of extended inter-layer time and laser remelting, all samples demonstrate a distinctly refined microstructure. This results in consistently high levels of microhardness and strength, with the “hardening” of the marginal zones. Eventually, the relationship between mechanical properties and microstructure sizes is established. This study provides valuable insights into the innovative designs and engineering applications of multi-scaled structures in LPBF using various materials.