Finite Element Analysis of Particle Pushing During Selective Laser Melting of AlSi10Mg/AlN Composites

Distribution of particles in metal matrix composites has a crucial effect on the efficiency of the mechanical reinforcing process. Re-melting and solidification of the matrix due to laser energy input during selective laser melting increases the probability of the secondary phase agglomeration. Reinforcement particles reallocate locally based on the speed of the solidification front through formation of the melt pool. Adequate energy input and optimized scanning speed are required not only to assure consolidation of the product, but also to control the melt pool geometry and solidification rate and consequently avoid particle pushing and clustering. A finite element model was developed to exhibit the interaction of aluminum nitride particles with the AlSi10Mg melt pool with respect to the solidification front. The model shows that the critical solidification conditions define whether engulfing or particle pushing take place; as an essential consideration when manufacturing metal matrix composites through selective laser melting.