An ultrastrong and thermal-resistant aluminum (Al) alloy with dual strengthening sources consisting of hierarchical intermetallics and carbides was developed for laser powder bed fusion (L-PBF). The role of TiC in engineering the microstructure, mechanical properties, and thermal resistance of L-PBF AlFeCr was systematically investigated. The rapid cooling rate and spatiotemporal variation of solidification conditions engender a refined and heterogeneous microstructure in the as-built AlFeCr. This microstructure comprises hierarchical intermetallics, specifically the quasicrystalline icosahedral phase (i-phase) and the θ-Al13(Fe,Cr)2-4 phase at the melt pool boundary, along with fibrous eutectic structures in the melt pool interior. The addition of TiC particles refines the grains through heterogeneous nucleation, which helps heal cracks in AlFeCr. The introduction of TiC improves the long-term thermal stability of AlFeCr by stabilizing the i-phase due to the slower diffusion of Ti relative to Fe and Cr, and by suppressing the coarsening of platelet-like Al13Fe4. The L-PBF TiC/AlFeCr demonstrates an ultrastrong tensile yield strength of 306 MPa at 300 °C and 174 MPa at 400 °C, surpassing those of typically L-PBF Al˗Ce-, Al˗Ni-, and Al˗Cu-based thermal-resistant Al alloys. Additionally, the stabilized hierarchical intermetallics contribute to a higher retention ratio of hardness and strength. The present work can shed light on designing ultrastrong and thermal-resistant Al alloys using dual strengthening sources, including carbides and hierarchical intermetallics.
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