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Effect of Surfactants and Hybrid Filler on Microstructural and Mechanical Properties of Al7075/TiC/Graphene Alloy Composite via Additive Manufacturing.

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Title: Effect of Surfactants and Hybrid Filler on Microstructural and Mechanical Properties of Al7075/TiC/Graphene Alloy Composite via Additive Manufacturing.
Authors: Babu, M. Anandh1 (AUTHOR) anandhcivil@gmail.com, Mohan, R.2 (AUTHOR) rmohan12@gmail.com, Latha, R.3 (AUTHOR) latharcse@krce.ac.in, Prabhu, P.4 (AUTHOR) drprabhuspalanisamy@gmail.com, Venkatesh, R.5 (AUTHOR) venkidsec@gmail.com, Prabagaran, S.6 (AUTHOR) thirums2012@gmail.com, Mohanavel, Vinayagam7 (AUTHOR) mohanavel2k18@gmail.com, Soudagar, Manzoore Elahi M.8,9 (AUTHOR) me.soudagar@gmail.com, Seikh, A. H.10 (AUTHOR) asifulhs.dr@hotmail.com
Source: Journal of Materials Engineering & Performance. Feb2026, Vol. 35 Issue 4, p3365-3376. 12p.
Subjects: Aluminum alloys, Composite materials, Microstructure, Titanium carbide, Three-dimensional printing, Mechanical behavior of materials, Surface active agents, Graphene
Abstract: The aluminum alloy composite processed with additive manufacturing technology (laser powder bed melting—LPBM) has better microstructural and mechanical properties and is familiar with making design freedom geometry. However, the combinations of composite powder found agglomeration, porosity due to high laser energy, and micro hot cracks, leading to a reduction in the functional properties of the composite. This research intends to overcome the above challenges and enrich the microstructural and mechanical properties of aluminum alloy (Al7075) powder blended with 0.5 wt.% graphene and 2.5-7.5 wt.% of titanium carbide (TiC) nanoparticles via a high-energy ball milling process, associated with 1% polyvinyl alcohol surfactants prevents the agglomeration. With the support of the laser powder bed melting process (LPBM), the Al7075/graphene/TiC composite is prepared with a 70 µm hatching distance with 60% overlap under argon build atmosphere, which helps to reduce the oxide formation. The LPBM-developed samples are involved in the aging process to limit the residual stress, which assists in determining the hot cracks. Effects of LPBM processing and filler on microstructural, physical, and mechanical properties are studied. The transmission electron microscope (TEM) analyzed image shows homogenous particle dispersion with improved interfacial bonding strength, with a grain size from 6 to 18 µm. The LPBM processed Al7075/1 wt.% graphene/7.5 wt.% TiC sample is 0.47% of porosity, optimum tensile strength (598 MPa), reduced elongation (7.2%), optimum impact strength (15.3 J/mm2), and improved microhardness of 228HV, respectively. [ABSTRACT FROM AUTHOR]
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Database: Engineering Source
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Abstract:The aluminum alloy composite processed with additive manufacturing technology (laser powder bed melting—LPBM) has better microstructural and mechanical properties and is familiar with making design freedom geometry. However, the combinations of composite powder found agglomeration, porosity due to high laser energy, and micro hot cracks, leading to a reduction in the functional properties of the composite. This research intends to overcome the above challenges and enrich the microstructural and mechanical properties of aluminum alloy (Al7075) powder blended with 0.5 wt.% graphene and 2.5-7.5 wt.% of titanium carbide (TiC) nanoparticles via a high-energy ball milling process, associated with 1% polyvinyl alcohol surfactants prevents the agglomeration. With the support of the laser powder bed melting process (LPBM), the Al7075/graphene/TiC composite is prepared with a 70 µm hatching distance with 60% overlap under argon build atmosphere, which helps to reduce the oxide formation. The LPBM-developed samples are involved in the aging process to limit the residual stress, which assists in determining the hot cracks. Effects of LPBM processing and filler on microstructural, physical, and mechanical properties are studied. The transmission electron microscope (TEM) analyzed image shows homogenous particle dispersion with improved interfacial bonding strength, with a grain size from 6 to 18 µm. The LPBM processed Al7075/1 wt.% graphene/7.5 wt.% TiC sample is 0.47% of porosity, optimum tensile strength (598 MPa), reduced elongation (7.2%), optimum impact strength (15.3 J/mm2), and improved microhardness of 228HV, respectively. [ABSTRACT FROM AUTHOR]
ISSN:10599495
DOI:10.1007/s11665-025-11873-4