Uniform Phase Distribution Research Articles

High-energy ball milling and spark plasma sintering of molybdenum - lanthanum oxide (Mo-La2O3) and molybdenum – lanthanum zirconate (Mo-La2Zr2O7) composite powders

The current study is focused on the preparation of Mo-10 vol%La2O3 and Mo-10 vol% La2Zr2O7 composite powders via low- and high-energy ball milling approaches as potential candidates for near-future high-temperature structural applications. The mechanical milling parameters play a critical role on the final powder's microstructure. When using the high-energy milling mode (using 800 rpm, ball-to-powder ratio (BPR) 100: 6), the homogeneous powder agglomerates are formed with refined laminated microstructure and more uniform ceramic phase distribution in both Mo-La2O3 and Mo-La2Zr2O7 systems compared to the powders produced by means of the low-energy milling mode (using 350 rpm, BPR 100: 6), where inhomogeneous powder mixture with less embedding of ceramic phases into Mo agglomerates was obtained. This study also focuses on the evaluation of high-temperature phase and microstructural stability of the produced composite powders treated at the temperature of 1300 °C under the different gaseous environments, including ambient, inert and reducing atmospheres. The Mo-10 vol% La2Zr2O7 composite powder exhibited better thermal stability during the high-temperature exposure in all tested atmospheres in comparison with the Mo-La2O3 composite powder, since it revealed less intensive formation of the intermediate phases, such as lanthanum oxymolybdates. Therefore, the Mo-10 vol% La2Zr2O7 composite powder was used further for consolidation by means of spark plasma sintering at 1600 °C. The successful production of Mo-La2Zr2O7 composite with homogeneous distribution of ceramic phase, the grain size about of 5 μm, and hardness of 3.4 GPa was not reported so far.

Spatial characteristics of nickel-titanium shape memory alloy fabricated by continuous directed energy deposition

Additive manufacturing has been adopted to process nickel‑titanium shape memory alloys due to its advantages of flexibility and minimal defects. The current layer-by-layer method is accompanied by a complex temperature history, which is not beneficial to the final characteristics of shape memory alloys. In this study, a continuous directed energy deposition method has been proposed to improve microstructure uniformity. The spatial characterization of nickel‑titanium shape memory alloy fabricated by continuous directed energy deposition is investigated to study the temperature history, phase constituent, microstructure, and mechanical properties. The results indicate that the fabricated specimen has a monotonic temperature history, relatively uniform phase distribution and microstructure morphology, as well as high compressive strength (2982 MPa–3105 MPa) and strain (37.7%–41.1%). The reported method is expected to lay the foundation for spatial control during the printing of functional structures.

Особливості засвоєння лігатури Al-10Mo електронно-променевої виплавки в рідкому алюмінії та сплаві AlSi9Cu3

The work is devoted to the Al-10Mo electron-beam prepared master-alloy modifying phases dissolution and assimilation features determination. It is shown that the obtained master-alloy is characterized by uniform distribution and high dispersion of molybdenum aluminide particles. When studying the process of dissolving the master-alloy in pure aluminum, it was determined that the time of modification of the melt more than 20 minutes at a temperature of 740 ± 10 ° C leads to the most complete destruction of the original intermetallics Al22Mo5 and Al17Mo4 and the formation of smaller and evenly distributed particles Al5Mo and Al12Mo with dimensions about 2 μm. As the molybdenum content decreases, the dispersion of the modifying phases and the uniformity of their distribution increase. Increasing the temperature and exposure time do not improve the assimilation of the modifier. The Al-10Mo master-alloy, obtained in the conditions of electron-beam casting technology, has a number of characteristics that allow to consider it as more efficient and cost-effective, compared to known analogues. This is due to the much higher concentration of molybdenum in the modifier (10% wt.), as well as fine dispersion and uniform distribution of the modifying phases. The nonequilibrium composition of aluminides inherent in the ligatures obtained under these conditions contributes to their significant grinding and refining after addition into aluminum melts. The stoichiometry of the phases from Al22Mo5 and Al17Mo4 changes to Al12Mo, which serve as crystallization centers and have a size of about 1 μm, dissolves and changes. The example of industrial casting alloy AlSi9Cu3 shows complete and effective assimilation of the master-alloy in a short time of 5 minutes at a temperature of 740 ± 10 ° C. Such indicators are more economic, in comparison with standard industrial ones, for which both higher temperature of melt preparing ant longer lifetime in liquid state after modification are necessary. Keywords: master-alloys, Al-Mo, modifications, aluminum alloys, AlSi9Cu3, resource saving.

Features of the Synthesis of the Dispersed TiC Phase with Nickel Nanostructures on the Surface to Create an Aluminum-Based Metal Composite.

The development of new composites with improved functional properties is the important task of modern materials science. The composites must be structurally organized to provide improved properties. For metal-ceramic composites, there is a need for a uniform distribution of the dispersed ceramic phase in the bulk metallic matrix The modification of the dispersed ceramic phase surface with a metal coating is one of the more effective ways to accomplish this. Particularly, in this work, the conditions of Ni nanolayer deposition on titanium carbide (TiC) particles were studied. The goal was to create core–shell particles with a thickness of the Ni coating on TiC not exceeding 90 nm. Preliminary work was also carried out to study the effect of the dispersed phase composition on the mechanical properties of the composite with an Al matrix.

Improvement of electrical and mechanical properties of In-48Sn solder bumps for flexible LED signage using Cu-Ag nanoparticles

This study aimed to enhance the mechanical strength of In-48Sn alloy solder bumps without the loss of electrical conductance for application of flexible electronic devices. As a simple method for controlling the mechanical strength, Cu nanoparticles were added to the In-48Sn solder paste during paste formulation. The addition of Ag-encapsulated Cu nanoparticles effectively improved the shear strength without loss of electrical conductance while the addition of Cu nanoparticles deteriorated both mechanical and electrical properties. The development of a dense or coarse microstructure during the soldering process was sensitively dependent on the surface condition and the content of nanoparticles. In particular, the uniform distribution of nanoparticles and alloy phases in β-In3Sn phase was critical for the control of mechanical strength of excessively ductile In-48Sn solder. As a result, the addition of 6 wt% Ag-encapsulated Cu nanoparticles improved the shear strength from 18.7 to 49.5 MPa and their electrical resistance from 0.23 to 0.1 mΩ. Flexible LED signage interconnected using these solder bumps performed very well after 100 000 cycles of bending test.

Acoustic spoof surface plasmon polaritons for filtering, isolation and sensing

We study a waveguide structure supporting acoustic spoof plasmon polaritons (aSSPPs) perturbed by a defect, whose specifically tailored geometry enables controllable transmission characterized by a uniform phase distribution and very steep narrowband response. The structure is analyzed using transmission-line theory and numerical simulations, providing evidence for its use in advanced filters, isolators and sensor technology. In order to demonstrate the applicability of the aSSPP waveguide with defect, two selective narrowband filter designs are discussed and explored. Furthermore, we propose an acoustic isolator that exploits steady fluid flow to break reciprocity and provide large isolation in a narrowband region. We also propose a sensor for liquid analytes, in which the grooves of the aSSPP waveguide serve as microfluidic channels, while the sensing principle is based on the spectral shift of the transmission peak for different mixtures of water and glycerol. The sensor shows a good sensitivity and fast response, with a potential for further development for applications in water quality monitoring.

Al/SiC nanocomposites with enhanced thermomechanical properties obtained from microwave plasma-treated nanopowders

Al-based composites with enhanced thermomechanical properties are in high demand. However, obtaining a uniform distribution of the strengthening phase in the metal matrix and achieving a strong metal/ceramic interface is still a great challenge. In this work, nanoAl/nanoSiC powder mixtures after high-energy ball milling were treated with Ar microwave plasma. Plasma processing was designed to remove the initial oxide film covering Al nanoparticles (NPs) and adsorbed impurities from the surface of SiC NPs, improve the wetting of SiC with Al melt, prevent SiC nanoparticle agglomeration, and ensure their uniform distribution in the metal matrix. During plasma treatment, Al/SiC composite particles were obtained, which were subsequently utilized as ready-made structural blocks with uniformly distributed reinforcing SiC NPs to obtain Al/SiC composites with 5, 10, and 30 wt% of SiC. Spark plasma sintered Al/SiC composites using plasma-treated powder mixtures showed approximately 20% higher tensile strength. The addition of 10% SiC led to an increase in hardness by 480% (145 HV), tensile strength by 70% (317 MPa) and 95% (238 MPa) at 25 °C and 500 °C, respectively, compressive strength by 135% (578 MPa), and wear resistance by 35–50%. The effect of point defects at the Al/SiC interface, such as impurity oxygen atoms and Si monovacancies, on the binding energy and temperature-dependent critical shear stress at the interface was assessed using molecular dynamics simulations with machine learning interatomic potentials. Our study demonstrated that the plasma-chemical treatment of Al/SiC powder mixtures is a promising approach for improving the thermomechanical properties of the Al/SiC composites.

Improvement in microstructure uniformity and mechanical properties of surface modified graphene reinforced Ni-based composites by laser deposition

Graphene (Gr) is regarded as one of the promising nano reinforcement of metal matrix composites (MMCs) to improve the comprehensive performance owing to its superior physical and mechanical properties recently. However, the agglomeration and survivability at high-temperature of Gr as well as the compatibility between Gr and metal, have severely restricted the application of Gr in MMCs. Herein, the surface modification coupled with a mixing method without ball-milling was employed to protect Gr from the structural damage. Then, the modified Gr (CoFe@Gr) reinforced Ni-based alloy composites were fabricated via laser deposition technique in an argon protective atmosphere. The results showed that the pristine Gr nanosheets were successfully incorporated into composites, but some of them were transformed into the nanospheres while others formed “core-shell” structure with carbides under the high-energy laser irradiation. Compared with alloys adding Gr directly, the addition of CoFe@Gr composite powders not only promoted the uniform distribution of the second phases in matrix phase but also inhibited the generation of the pores defects resulted from the burning of Gr without surface modification. The changes in microstructure contributed to the lower coercivity of composites. Moreover, the micro-hardness and compressive strength values of composites were increased by 12.55% and 45.50% as compared with that of as-deposited alloys, respectively. This was mainly attributed to the improved interface compatibility between Gr and Ni matrix, the thermal mismatch effect and the second phase strengthening effect. This work is expected to provide a technique guidance for Gr reinforced MMCs that the fabrication conditions requiring high temperature.

Long-sized rods of Al2O3–SiC–TiB2 ceramic composite material obtained by SHS-extrusion: Microstructure, X-ray analysis and properties

Long-sized rods of Al2O3–SiC–TiB2 ceramic composite material were obtained by SHS-extrusion. The material was synthesized by self-propagating high-temperature synthesis (SHS) followed by high-temperature shear deformation. Ceramic samples app up to 465 mm in length and 5 mm in diameter were obtained. According to the results of XRD and SEM the obtained rods have a composite structure. The matrix is Al2O3 with distributed titanium diboride and silicon carbide particles. A uniform phase distribution was observed along the entire length of the rod. The microhardness of the matrix was 25–26 GPa, that of the dispersion-strengthening phases - 32–34 GPa. Heat resistance tests showed that during heat treatment at T = 1000 °C for 21 h, the sample specific weight gain and its real rate were 8.3 g/m2 and 1 g/(m2∙h), respectively. The density, hardness and electrical resistivity of the samples obtained in this work were 3.27 g/cm3, 19.5 GPa, 3.1∙10−5 Ohm∙m, respectively.

A comparative study of tensile properties of eutectic Al-Si / ZrO2 composites fabricated by spray forming and stir casting methods

ABSTRACT The study aims to investigate the microstructural and mechanical properties of Al-12.5%Si matrix composites reinforced with ZrO2 were fabricated by spray forming method and stir casting (SC) technique by varying reinforcement of 2%, 6% and 10 wt.% ZrO2 powder (size 25 μm).The spray-formed (SD) composites were subjected to hot (400°C) isostatic pressing to reduce the porosity. The microstructure of spray-formed and SC composites were examined using optical and SEM/ EDS. The microstructure of the spray-formed composites showed uniform distribution of fine Si, eutectic phase and ZrO2 particles in the equiaxed Al-matrix. In contrast, SC composites consist of a coarse Si, needle like eutectic phase and clustering of reinforcement particles at grain junctions as a continuous network along the grain boundaries. The hardness, ultimate tensile strength of both spray-formed and SC composites improved as the ZrO2 content increased, while yield strength decreased. Spray-formed composites showed better mechanical properties. This was attributed to uniform distribution fine of Si particles, reinforced particles, equiaxed matrix induced during spray deposition process. Tensile fracture surface of spray-formed composites possess ductile and cleavage fractures. SC composites showed intragranular cracks in coarse Si particles and increase in micro-cracks with increasing reinforcement.

Effect of High Pressure and Temperature on the Evolution of Si Phase and Eutectic Spacing in Al-20Si Alloys

The microstructure of the Si phase in Al-20Si alloys solidified under high pressure was investigated. The results demonstrate that the morphology of Si phase transformed (bulk→short rod→long needle) with the increase of superheat temperature under high pressure. At a pressure of 3 GPa and a superheat temperature of 100 K, a microstructure with a uniform distribution of fine Si phases on the α-Al matrix was obtained in the Al-20Si alloy. In addition, a mathematical model was developed to analyze the spacing variation of the lamellar Al-Si eutectics under the effect of pressure. The lamellar Al-Si eutectics appeared at 2 GPa and superheat temperatures of 70–150 K, and at 3 GPa and superheat temperatures of 140–200 K. With the increase of pressure from 2 GPa to 3 GPa, the average spacing of lamellar Al-Si eutectics decreased from 1.2–1.6 μm to 0.9–1.1 μm. In binary alloys, the effect of pressure on the eutectic spacing is related to the volume change of the solute phase from liquid to solid. When the volume change of the solute phase from liquid to solid is negative, the lamellar eutectic spacing decreases with increasing pressure. When it is positive, the eutectic spacing increases with increasing pressure.

The Structure and Mechanical Properties of Hemp Fibers-Reinforced Poly(ε-Caprolactone) Composites Modified by Electron Beam Irradiation

The need for the development of new biodegradable materials and modification of the properties the current ones possess has essentially increased in recent years. The aim of this study was the comparison of changes occurring in poly(ε-caprolactone) (PCL) due to its modification by high-energy electron beam derived from a linear electron accelerator, as well as the addition of natural fibers in the form of cut hemp fibers. Changes to the fibers structure in the obtained composites and the geometrical surface structure of sample fractures with the use of scanning electron microscopy were investigated. Moreover, the mechanical properties were examined, including tensile strength, elongation at break, flexural modulus and impact strength of the modified PCL. It was found that PCL, modified with hemp fibers and/or electron radiation, exhibited enhanced flexural modulus but the elongation at break and impact strength decreased. Depending on the electron radiation dose and the hemp fibers content, tensile strength decreased or increased. It was also found that hemp fibers caused greater changes to the mechanical properties of PCL than electron radiation. The prepared composites exhibited uniform distribution of the dispersed phase in the polymer matrix and adequate adhesion at the interface between the two components.

A novel receiver-transmitter metasurface for a high-aperture-efficiency Fabry-Perot resonator antenna* *Project supported by the National Natural Science Foundation of China (Grant No. 61871394) and Natural Science Foundation of Shanxi Province, China (Grant No. 2020JQ-482).

This paper presents a novel coupled receiver–transmitter metasurface (MS) which is used to realize a high-aperture-efficiency Fabry–Perot resonator antenna. The unit cell of the MS adopts a slot-coupling procedure to realize energy transmission from the receiver patch to the radiator patch. This approach makes it easier to independently control the transmission magnitude and phase. Based on this characteristic, the transmission coefficients of different unit cells on the MS can be optimized by a genetic algorithm. Then, nearly uniform electric amplitude and phase distribution across the aperture field of the antenna are achieved. Therefore, the gain and aperture efficiency of the antenna are improved. A prototype of the optimized antenna is fabricated and measured to validate the design. The measured gain of the fabricated antenna reaches 17.3 dBi with an aperture efficiency of 94.5%. A higher aperture efficiency is obtained with the proposed antenna which has a low profile and simple structure.

Parametric study of gas−liquid two-phase flow field in horizontal stirred tank

Based on Fluent software, the gas−liquid two-phase flow in the horizontal stirred tank was simulated with SST k−ω turbulence model, Eulerian−Eulerian two-fluid model, and multi-reference flame method. The mixing process in the tank was calculated by tracer method. The results show that increasing the rotating speed or gas flow is conducive to a more uniform distribution of the gas phase and accelerates the mixing of the liquid phase. When the rotating speed exceeds 93 r/min, the relative power demand remains basically constant. The change in the inclination angle of the upper impeller has minimal effect on the gas phase distribution. When the inclination angle is 50°, the relative power demand reaches the maximum. An appropriate increase in the impeller distance from the bottom improves the gas holdup and gas phase distribution but increases the liquid phase mixing time.

Розробка технології дисперсного модифікування жароміцних нікелевих сплавів для лопаток газотурбінних двигунів

The paper proposes means of improving the properties of nickel alloys for aircraft gas turbine engines by improving the existing alloys. The efficiency of an aircraft engine depends on the quality of the turbine rotor blades, which are made of heat-resistant alloys. According to the studies, the obtained results of pilot tests of a complex of mechanical properties, high-temperature corrosion of a multicomponent high-temperature nickel alloy ХН59МВТКЮЛ (Ni-Cr-W-Co-Al-Ti-Mo systems). The paper proposes the use of modifiers. An effective means of dispersing the structural components of alloys at the macro and micro levels is the modification of multicomponent alloys with dispersed and nano dispersed compositions. Based on titanium nitride powder, a technological regime for modifying nickel melt with dispersed compositions of plasma chemical synthesis has been developed. The modifier was used in tablet form. Investigated different dosages of the modifier: 0.1…0.03 % by weight. The proposed method allows, with minimal losses at the melting stage, to introduce the required amount of modifier. The temperature and time parameters of the modification are 16500С, the modifier action time is 5…7 minutes. Investigations of the complex mechanical properties and the peculiarities of the formation of the structure of the modified alloy have been carried out. According to the research results, significant refinement of the alloy grain was obtained in comparison with the initial state. The modification led to an increase in mechanical properties: strength by 10 %, impact strength by 35...40 %. Comparison of the nano-modified alloy with the obtained one made it possible to increase the corrosion resistance of the ХН59МВТКЮЛ alloy in an oxidizing environment. At a temperature of 1000 0С, the corrosion depth decreased by 15 %. An increase in resistance to high-temperature corrosion is associated with a more uniform distribution of excess phases in the structure of the modified alloy. The mechanism of action of refractory particles of a modifier in a nickel melt, which are the nuclei of primary crystallization, has been established. The results of the work are of practical value in the manufacture of rotor blades from high-quality heat-resistant nickel alloys with increased parameters of heat resistance and heat resistance.

Interface regulation enabling three-dimensional Li1.3Al0.3Ti1.7(PO4)3-reinforced composite solid electrolyte for high-performance lithium batteries

Composite solid electrolyte (CSE) consisting of Li+ conductive fillers and polymer matrix has become attractive for high energy-density lithium batteries. Current researches focus on the “ceramic in polymer”-type CSE due to the severe agglomeration of ceramic particles. Consequently, the destroyed percolation network impedes the further improvement in ionic conductivity. In this work, we report a novel structural design of ceramic-enriched CSE consisting of three-dimensional (3D) interconnected Li1.3Al0.3Ti1.7(PO4)3 (LATP), polyvinylidene fluoride (PVDF) and LiN(SO2)2(CF3)2 (LiTFSI). The 3D LATP network is constructed through the surface functionalization of LATP particles by polymethyl methacrylate (PMMA). Owing to the intermolecular interaction between PMMA and PVDF, the incorporation of PMMA-coated LATP (denoted as LATP@PMMA) enables the uniform distribution of ceramic phase and generates interconnected LATP network. Noticeably, such an electrolyte maximizes the utilization of inorganic fillers through the facile treatment of zero-dimensional materials, which is comparable to those 3D template-derived fillers. Furthermore, continuous Li+ conduction pathways through LATP framework and LATP/PVDF interphase are guaranteed by the enhanced affinity of LATP towards PVDF matrix and the intrinsic Li+ complexation capability of PMMA. Remarkable cycling performances of the LiNi0.5Co0.2Mn0.3O2/LATP@PMMA-PVDF/Li batteries confirm the feasibility of 3D ceramic-enriched composite electrolyte in the application of solid-state lithium batteries.

Fabrication and properties of Cf/(Ti0.2Zr0.2Hf0.2Nb0.2Ta0.2)C-SiC high-entropy ceramic matrix composites via precursor infiltration and pyrolysis

In this work, Cf/(Ti0.2Zr0.2Hf0.2Nb0.2Ta0.2)C-SiC high-entropy ceramic matrix composites were reported for the first time. Based on the systematic study of the pyrolysis and solid-solution mechanisms of (Ti0.2Zr0.2Hf0.2Nb0.2Ta0.2)C precursor by Fourier transform infrared spectroscopy, TG-MS and XRD, Cf/(Ti0.2Zr0.2Hf0.2Nb0.2Ta0.2)C-SiC with uniform phase and element distribution were successfully fabricated by precursor infiltration and pyrolysis. The as-fabricated composites have a density and open porosity of 2.40 g/cm3 and 13.32 vol% respectively, with outstanding bending strength (322 MPa) and fracture toughness (8.24 MPa m1/2). The Cf/(Ti0.2Zr0.2Hf0.2Nb0.2Ta0.2)C-SiC composites also present excellent ablation resistant property at a heat flux density of 5 MW/m2, with linear and mass recession rates of 2.89 μm/s and 2.60 mg/s respectively. The excellent combinations of mechanical and ablation resistant properties make the Cf/(Ti0.2Zr0.2Hf0.2Nb0.2Ta0.2)C-SiC composites a new generation of reliable ultra-high temperature materials.

Grain refinement impact on the mechanical properties and wear behavior of Mg-9Gd-3Y-2Zn-0.5Zr alloy after decreasing temperature reciprocating upsetting-extrusion

Based on the deforming technique of severe plastic deformation (SPD), the grain refinement of a Mg-9Gd-3Y-2Zn-0.5Zr alloy treated with decreasing temperature reciprocating upsetting-extrusion (RUE) and its influence on the mechanical properties and wear behavior of the alloy were studied. The RUE process was carried out for 4 passes in total, starting at 0 °C and decreasing by 10 °C for each pass. The results showed that as the number of RUE passes increased, the grain refinement effect was obvious, and the second phase in the alloy was evenly distributed. Room temperature tensile properties of the alloy and the deepening of the RUE degree showed a positive correlation trend, which was due to the grain refinement, uniform distribution of the second phase and texture weakening. And the microhardness of the alloy showed that the microhardness of RUE is the largest in 2 passes. The change in microhardness was the result of dynamic competition between the softening effect of DRX and the work hardening effect. In addition, the wear resistance of the alloy showed a positive correlation with the degree of RUE under low load conditions. When the applied load was higher, the wear resistance of the alloy treated with RUE decreased compared to the initial state alloy. This phenomenon was mainly due to the presence of oxidative wear on the surface of the alloy, which could balance the positive contribution of severe plastic deformation to wear resistance to a certain extent.

On the Direct Extrusion of Solder Wire from 52In-48Sn Alloy

In this article, technology for producing wire and rod solder from 52In-48Sn alloy has been developed and investigated in the conditions of small-scale production. The use of direct extrusion of wire and rods instead of traditional technology for producing solder, which includes pressing, rolling and drawing, can significantly reduce the fleet of required equipment. Using only a melting furnace and a hydraulic press, solder wires and rods can be produced in various sizes. Shortening the production cycle allows you to quickly fulfill small orders and be competitive in sales. This article develops a mathematical model of direct extrusion, which allows you to calculate the extrusion ratio, extrusion speed and pressing force. The results of modeling the process of extrusion of wire Ø2.00 mm and rods Ø8.0 mm made of 52In-48Sn alloy are presented. The temperature of the solder and the tool is simulated in software QForm based on the finite element method. Experimental results of manufacturing Ø2.0 mm solder wire and Ø8.0 mm rods are presented. The microstructure of the direct extruded solder is a eutectic of phases γ and β. Energy-dispersive X-ray spectroscopy (EDS) mapping of the 52In-48Sn alloy showed that the solder obtained by direct extrusion has a uniform distribution of structural phases. The developed technology can be used in the manufacture of wires and rods from other low-melting alloys.

Investigation of melt-growth alumina/aluminum titanate composite ceramics prepared by directed energy deposition

Al2O3/Al6Ti2O13 composite ceramics with low thermal expansion properties are promising for the rapid preparation of large-scale and complex components by directed energy deposition-laser based (DED-LB) technology. However, the wider application of DED-LB technology is limited due to the inadequate understanding of process conditions. The shaping quality, microstructure, and mechanical properties of Al2O3/Al6Ti2O13 (6 mol% TiO2) composite ceramics were systematically investigated as a function of energy input in an extensive process window. On this basis, the formation mechanism of solidification defects and the evolution process of microstructure were revealed, and the optimized process parameters were determined. Results show that high energy input improves the fluidity of the molten pool and promotes the uniform distribution and full growth of constituent phases, thus, facilitating the elimination of solidification defects, such as pores and strip gaps. In addition, the microstructure size is strongly dependent on the energy input, increasing when the energy input increases. Moreover, the morphology of the α-Al2O3 phase gradually transforms from cellular into cellular dendrite with increasing energy input due to changing solidification conditions. Under the comprehensive influence of solidification defects and microstructure size, the fracture toughness and flexural strength of Al2O3/Al6Ti2O13 composite ceramics present a parabolic law behavior as the energy input increases. Optimal shaping quality and excellent mechanical properties are achieved at an energy input range of 0.36−0.54 W*min2 g−1 mm−1. Within this process window, the average microhardness, fracture toughness, and flexural strength of Al2O3/Al6Ti2O13 composite ceramics are up to 1640 Hv, 3.87 MPa m1/2, and 227 MPa, respectively. This study provides practical guidance for determining the process parameters of DED-LB of melt growth Al2O3/Al6Ti2O13 composite ceramics.