Abstract
The Laser Powder Bed Fusion (LPBF) process for Al-Cu-Mg alloys, such as the 2024 alloy, is fraught with challenges, primarily due to thermal cracking and the complexity of fabricating lattice structures. This study presents a systematic exploration of the LPBF process capabilities for 2024 Al alloy, a representative Al-Cu-Mg alloy, by incorporating cost-effective micron-scale TiCN ceramic reinforcement particles. The introduction of TiCN significantly modifies the consolidation mechanisms of the 2024 Al alloy matrix during LPBF process, effectively eliminating thermal cracking, refining the matrix grain size, and therefore significantly enhancing the mechanical behavior of Al-Cu-Mg alloys. Nonetheless, this study incorporates advanced lattice structure design to the LPBF processing of 2024-5 vol% TiCN composite material. When compared to Cubic and Diamond structures, Schwarz one demonstrates superior compressive strength, which suggests that higher surface area design of the lattice structures may contribute to the improved mechanical properties. This research offers a novel and economical approach to the development of high-performance Al-Cu-Mg materials tailored for LPBF, laying a groundwork for applications in aerospace, automotive manufacturing, and other sectors.
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