Influence of SiC Reinforcement and Laser Energy Density on AlSi10Mg Parts via LPBF

Influence of SiC Reinforcement and Laser Energy Density on AlSi10Mg Parts via LPBF | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Influence of SiC Reinforcement and Laser Energy Density on AlSi10Mg Parts via LPBF Karolis Stravinskas, Nabee Maqsood, Ada Steponavičūtė, Romuald Petkevič, and 3 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7583453/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract This study investigates the effect of 10 wt.% SiC ceramic reinforcement and laser energy density on the structural, mechanical, and thermal performance of AlSi10Mg components fabricated via Laser Powder Bed Fusion. Samples of both unreinforced and SiC-reinforced AlSi10Mg were produced across a broad energy density range (35–200 J/mm³). The base alloy achieved optimal density (2.63 g/cm³) and tensile strength (246.5 MPa) at 100 J/mm³, while the composite reached peak performance at 140 J/mm³ with a density of 2.62 g/cm³ and tensile strength of 204.6 MPa. Despite a 17% drop in strength, the composite exhibited a > 30% hardness increase. XRD confirmed in-situ formation of Al₄C₃, indicating chemical reactivity between Al and SiC. Higher energy densities led to increased surface roughness and porosity in the composite due to melt pool instability. The thermal expansion behavior of the composite was more stable, with a peak CTE of 18 µm/m·°C, reflecting a 28% reduction compared to the base alloy (25 µm/m·°C). Thermal conductivity decreased from 170 to 100 W/m·K upon SiC addition. These results underscore the dual role of SiC as a strengthening agent and a thermal disruptor, necessitating precise energy control. The findings establish clear process–structure–property relationships and provide guidelines for fabricating dimensionally stable, high-performance AlSi10Mg–SiC parts for demanding thermal environments. Additive Manufacturing Laser Powder Bed Fusion Metal Matrix Composites Metal Ceramic Laser Energy Density Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7583453","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":517055500,"identity":"4eb34b95-c033-4959-aaeb-83e8f2efa3bf","order_by":0,"name":"Karolis 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LPBF","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Additive Manufacturing, Laser Powder Bed Fusion, Metal Matrix Composites, Metal, Ceramic, Laser Energy Density","lastPublishedDoi":"10.21203/rs.3.rs-7583453/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7583453/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThis study investigates the effect of 10 wt.% SiC ceramic reinforcement and laser energy density on the structural, mechanical, and thermal performance of AlSi10Mg components fabricated via Laser Powder Bed Fusion. Samples of both unreinforced and SiC-reinforced AlSi10Mg were produced across a broad energy density range (35\u0026ndash;200 J/mm\u0026sup3;). The base alloy achieved optimal density (2.63 g/cm\u0026sup3;) and tensile strength (246.5 MPa) at 100 J/mm\u0026sup3;, while the composite reached peak performance at 140 J/mm\u0026sup3; with a density of 2.62 g/cm\u0026sup3; and tensile strength of 204.6 MPa. Despite a 17% drop in strength, the composite exhibited a\u0026thinsp;\u0026gt;\u0026thinsp;30% hardness increase. XRD confirmed in-situ formation of Al₄C₃, indicating chemical reactivity between Al and SiC. Higher energy densities led to increased surface roughness and porosity in the composite due to melt pool instability. The thermal expansion behavior of the composite was more stable, with a peak CTE of 18 \u0026micro;m/m\u0026middot;\u0026deg;C, reflecting a 28% reduction compared to the base alloy (25 \u0026micro;m/m\u0026middot;\u0026deg;C). Thermal conductivity decreased from 170 to 100 W/m\u0026middot;K upon SiC addition. These results underscore the dual role of SiC as a strengthening agent and a thermal disruptor, necessitating precise energy control. The findings establish clear process\u0026ndash;structure\u0026ndash;property relationships and provide guidelines for fabricating dimensionally stable, high-performance AlSi10Mg\u0026ndash;SiC parts for demanding thermal environments.\u003c/p\u003e","manuscriptTitle":"Influence of SiC Reinforcement and Laser Energy Density on AlSi10Mg Parts via LPBF","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-09-25 17:07:44","doi":"10.21203/rs.3.rs-7583453/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"75c67499-13d1-43c5-866d-e2b8c6212ce7","owner":[],"postedDate":"September 25th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2025-10-18T10:53:27+00:00","versionOfRecord":[],"versionCreatedAt":"2025-09-25 17:07:44","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-7583453","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7583453","identity":"rs-7583453","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}