Abstract:
【Objective】 This study aimed to address the scarcity of research on laser powder bed fusion(LPBF) of ceramic-reinforced metal composites, as systematic studies are lacking in material design, processing parameter optimization, and microstructure-mechanical property characterization. Given the demand for high-performance FeCrAl-based composites in high-temperature/corrosion-resistant fields, the work focused on developing LPBF strategies for WC/spherical cast tungsten carbide(CC)-reinforced Fe20 Cr5 Al composites, optimizing printing parameters, clarifying interfacial reaction mechanisms, and evaluating density/mechanical property improvements, thereby supporting practical applications and enriching additive manufacturing theory for metal matrix composites.【Method】 Fe20 Cr5 Al powder was used as the matrix, with WC and CC as reinforcements to prepare Fe20 Cr5 Al-20 vol.% WC/CC composite powders via mechanical mixing. The response surface method(RSM) was adopted to optimize LPBF parameters(laser power, scanning speed, hatch spacing). LPBF experiments were conducted, and the relative density was measured using the Archimedes method. Their microstructures, interfacial reactions, and element distributions were analyzed. Additionally, the hardness and compressive strength were evaluated with pure Fe20 Cr5 Al as the reference.【Result】 The results show that RSM effectively optimizes the LPBF parameters: Fe20 Cr5 Al-20 vol.% WC(231 W, 1 259 mm/s, 0.068 mm) and Fe20 Cr5 Al-20 vol.% CC(236 W, 1 280 mm/s, 0.06 mm). Both composites exhibit relative density above 96%. During LPBF, WC/CC reacts with the matrix to form Fe
3W
3C, accompanied by W/C diffusion into the matrix. Compared with pure Fe20 Cr5 Al, the composites show over 110% higher hardness and 80% higher compressive strength, confirming the significant strengthening effect of ceramic particles.【Conclusion】 LPBF is feasible for preparing high-performance WC/CC-reinforced Fe20 Cr5 Al composites. The optimal parameters ensure >96% relative density, and interfacial reactions(Fe
3W
3C formation + element diffusion) enhance interfacial bonding, which is key to improved mechanical properties. The remarkable performance enhancements provide a new approach for high-strength FeCrAl-based materials, filling the research gap in LPBF of ceramic-reinforced FeCrAl composites and offering theoretical/technical support for similar composites.