Metal Matrix Composites for Aerospace Produced by Additive Manufacturing

This study explores the characterisation of (A2618+Ti+B) multimaterial systems created by Directed Energy Deposition (DED). Test samples that were printed using different sets of machine process parameters (scanning speed, hatching distance, and layer thickness). Key techniques for porosity investigation using optical microscopy with ImageJ software and examining the microstructure using a scanning electron microscope. In general, the combined image analysis and microstructural characterization revealed a strong correlation between porosity regulation and the distribution of secondary phases. By optimizing the processing parameters, it is possible to achieve a dense Al matrix reinforced with TiB₂ precipitates, while avoiding excessive intermetallic clustering. These results provide the integration of image analysis and microstructural characterization demonstrates that porosity control and secondary phase distribution are strongly interlinked. Optimized processing parameters can therefore yield a dense Al matrix reinforced with beneficial TiB₂ precipitates while avoiding excessive intermetallic clustering. These findings provide that alloy design aimed at enhancing the mechanical performance and reliability of additively manufactured Al alloys.