Selective laser melting and functional properties of AlSi10Mg-based aluminum matrix composites with Cu, CuNi, and CuNiFeCo additives
https://doi.org/10.17073/1997-308X-2026-2-71-83
Abstract
AlSi10Mg-based aluminum matrix composites (AMCs) with additives of Cu, CuNi, and multicomponent CuNiFeCo alloy additives were fabricated by selective laser melting. The additives were prepared by solution combustion synthesis, and the composite powder mixtures were produced by mechanical processing in a planetary ball mill. The study examined the powder morphology, phase composition, and properties of compact samples with particular focus on their thermophysical and electrical behavior. The Cu-containing alloy additives markedly improved the functional performance of the materials: thermal conductivity increased by up to 55 %, and heat capacity increased by up to 15 % compared with the base AlSi10Mg alloy. Electrical conductivity decreased of up to 65 %, with the strongest effect observed for the multicomponent CuNiFeCo additive. The resulting AMCs combine enhanced thermophysical properties with reduced electrical conductivity, making them suitable for heat-dissipating and heat-resistant components in electronics and aerospace applications. Lower electrical conductivity may also be beneficial in radio-frequency modules, inductive components, and shielded electronic systems, where parasitic currents and eddy-current losses should be minimized. Because they compatible with selective laser melting, these materials are promising for the additive manufacturing of complex-shaped functional components, including heat-dissipating housing, heat sinks, and weight-optimized parts.
Supporting agencies: This study was supported by the Russian Science Foundation (grant No. 19-79-30025).
About the Authors
K. V. Kuskov
National University of Science and Technology “MISIS”
Russian Federation
Russian Federation
Kirill V. Kuskov – Leading Research Project Expert, Research Center of Engineering Ceramic Nanomaterials
1 Bld, 4 Leninskiy Prosp., Moscow 119049, Russia
A. A. Nepapushev
National University of Science and Technology “MISIS”
Russian Federation
Russian Federation
Andrey A. Nepapushev – Cand. Sci. (Eng.), Senior Research Scientist, Research Center of Engineering Ceramic
1 Bld, 4 Leninskiy Prosp., Moscow 119049, Russia Nanomaterials
D. O. Moskovskikh
National University of Science and Technology “MISIS”
Russian Federation
Russian Federation
Dmitry O. Moskovskikh – Cand. Sci. (Eng.), Director, Research Center of Engineering Ceramic Nanomaterials
1 Bld, 4 Leninskiy Prosp., Moscow 119049, Russia
References
1. Liao H., Li G., Liu Q. Ni-rich phases in Al–12%Si–4%Cu–1.2%Mn–x%Ni heat-resistant alloys and effect of Ni-alloying on tensile mechanical properties. Journal of Materials Engineering and Performance. 2019;28(9): 5398–5408. https://doi.org/10.1007/s11665-019-04307-5
2. Wang L., Makhlouf M., Apelian D. Aluminium die casting alloys: alloy composition, microstructure, and properties-performance relationships. International Materials Reviews. 1995;40(6):221–238. https://doi.org/10.1179/imr.1995.40.6.221
3. Nepapushev A.A., Kuskov K.V., Lopatkina S.V., Chernyshikhin S.V., Suvorova V.S., Moskovskikh D.O. Laser powder bed fusion of AlSi10Mg/W2B5 composite: powder preparation, phase transformations, and mechanical properties. Advanced Engineering Materials. 2025;27(9):2402676. https://doi.org/10.1002/adem.202402676
4. Suvorova V., Volodko S., Suvorov D., Chernyshikhin S., Nepapushev A., Korol A., Volkova L., Sokolov P., Khort A., Moskovskikh D. Enhanced microstructure and mechanical properties of ZrN-reinforced AlSi10Mg aluminum matrix composite. Scientific Reports. 2024;14(1):10152. https://doi.org/10.1038/s41598-024-58614-6
5. Suvorova V.S., Fedorenko L.V., Zhevnenko S.N., Zotov B.O., Egorov V.Yu., Zherebtsov D.D., Suvorov D.S., Khaydarov B.B., Kotyakova K.Yu., Nepapushev A.A., Kovalev I.A., Moskovskikh D.O., Chernyshikhin S.V. Laser powder bed fusion of AlN and ZrN reinforced AlSi10Mg matrix composites: Effect of wettability and volume fraction on microstructure and mechanical properties. International Journal of Lightweight Materials and Manufacture. 2025;8(4):469–482. https://doi.org/10.1016/j.ijlmm.2025.04.002
6. Mei J., Han Y., Sun J., Zu G., Song X., Zhu W., Ran X. Achieving high strength in selective laser melting AlSi10Mg alloy by adding microsized pure Cu particles. Materials Science and Engineering: A. 2023;880:145357. https://doi.org/10.1016/j.msea.2023.145357
7. de Moura D.A., de Gouveia G.L., Gomes L.F., Spinelli J.E. Understanding the effect of Ni content on microstructures and tensile properties of AlSi10Mg alloy samples under a variety of solidification rates. Journal of Alloys and Compounds. 2022;924:166496. https://doi.org/10.1016/j.jallcom.2022.166496
8. Jandaghi M.R., Aversa A., Manfredi D., Calignano F., Lavagna L., Pavese M. In situ alloying of AlSi10Mg–5 wt%Ni through laser powder bed fusion and subsequent heat treatment. Journal of Alloys and Compounds. 2022;904:164081. https://doi.org/10.1016/j.jallcom.2022.164081
9. Marola S., Gianoglio D., Bosio F., Aversa A., Lorusso M., Manfredi D., Lombardi M., Battezzati L. Alloying AlSi10Mg and Cu powders in laser Single Scan Tracks, melt spinning, and Laser Powder Bed Fusion. Journal of Alloys and Compounds. 2020;821:153538. https://doi.org/10.1016/j.jallcom.2019.153538
10. Cantor B., Chang I.T.H., Knight P., Vincent A.J.B. Microstructural development in equiatomic multicomponent alloys. Materials Science and Engineering: A. 2004; 375–377:213–218. https://doi.org/10.1016/j.msea.2003.10.257
11. Rogachev A.S. Structure, stability, and properties of high-entropy alloys. Physics of Metals and Metallography. 2020;121(8):733–764. https://doi.org/10.31857/S0015323020080094
12. Lee K.S., Bae B., Kang J.-H., Lim K.R., Na Y.S. Multi-phase refining of an AlCoCrFeNi high entropy alloy by hot compression. Materials Letters. 2017;198:81–84. https://doi.org/10.1016/j.matlet.2017.03.181
13. Tian F., Delczeg L., Chen N., Varga L.K., Shen J., Vitos L. Structural stability of NiCoFeCrAlx high-entropy alloy from ab initio theory. Physical Review B. 2013;88(8): 085128. https://doi.org/10.1103/PhysRevB.88.085128
14. Kuskov K.V., Nepapushev A.A., Aydinyan S., Shaysultanov D.G., Stepanov N.D., Nazaretyan K., Kharatyan S., Zakharova E.V., Belov D.S., Moskovskikh D.O. Combustion synthesis and reactive spark plasma sintering of non-equiatomic CoAl-based high entropy intermetallics. Materials. 2023;16(4):1490. https://doi.org/10.3390/ma16041490
15. Sun Z., Tan X., Wang C., Descoins M., Mangelinck D., Tor S.B., Jägle E.A., Zaefferer S., Raabe D. Reducing hot tearing by grain boundary segregation engineering in additive manufacturing: example of an AlxCoCrFeNi high-entropy alloy. Acta Materialia. 2021;204:116505. https://doi.org/10.1016/j.actamat.2020.116505
16. Zhu X., Liu S., Wang X., Wang G. Effect of solution and aging treatments on the microstructure and mechanical properties of dual-phase high-entropy alloy prepared by laser-powder bed fusion using AlSi10Mg and FeCoCrNi powders. Additive Manufacturing. 2023;70:103548. https://doi.org/10.1016/j.addma.2023.103548
17. Zhu X., Wang G., Wang X., Zhao G. Microstructure and mechanical properties of Al0.3FeCoCrNi high entropy alloy processed by laser powder bed fusion using FeCoCrNi and Al powder mixture. Materials Science and Engineering: A. 2022;848:143468. https://doi.org/10.1016/j.msea.2022.143468
18. Yermekova Z., Chernyshova E., Roslyakov S., Trusov G., Argunov E., Yurlov S., Moskovskikh D., Yudin S. Microstructure and thermoelectric properties of porous CaMnO3/CaMn2O4 composite prepared by spray solution combustion synthesis. Journal of the European Ceramic Society. 2024;44(11):6449–6459. https://doi.org/10.1016/j.jeurceramsoc.2024.04.012
19. Evdokimenko N., Yermekova Z., Roslyakov S., Tkachenko O., Kapustin G., Bindiug D., Kustov A., Mukasyan A.S. Sponge-like CoNi catalysts synthesized by combustion of reactive solutions: stability and performance for CO2 hydrogenation. Materials. 2022;15(15):5129. https://doi.org/10.3390/ma15155129
20. Mukasyan A.S., Epstein P., Dinka P. Solution combustion synthesis of nanomaterials. Proceedings of the Combustion Institute. 2007;31(2):1789–1795. https://doi.org/10.1016/j.proci.2006.07.052
21. Romanovski V., Roslyakov S., Trusov G., Periakaruppan R., Romanovskaia E., Chan H.L., Moskovskikh D. Synthesis and effect of CoCuFeNi high entropy alloy nanoparticles on seed germination, plant growth, and microorganisms inactivation activity. Environmental Science and Pollution Research. 2023;30(9):23363–23371. https://doi.org/10.1007/s11356-022-23918-5
22. Romanovski V., Sdobnyakov N., Roslyakov S., Kolosov A., Podbolotov K., Savina K., Kwapinski W., Moskovskikh D., Khort A. Bimetallic CuNi nanoparticle formation: solution combustion synthesis and molecular dynamic approaches. Inorganic Chemistry. 2024;63(52):24844–24854. https://doi.org/10.1021/acs.inorgchem.4c04260
23. Hojjatzadeh S.M.H., Parab N.D., Yan W., Guo Q., Xiong L., Zhao C., Qu M., Escano L.I., Xiao X., Fezzaa K., Everhart W., Sun T., Chen L. Pore elimination mechanisms during 3D printing of metals. Nature Communications. 2019;10(1):3088. https://doi.org/10.1038/s41467-019-10973-9
24. Nazarahari A., Fromm A.C., Ozdemir H.C., Klose C., Maier H.J., Canadinc D. Determination of thermal conductivity of eutectic Al–Cu compounds utilizing experiments, molecular dynamics simulations and machine learning. Modelling and Simulation in Materials Science and Engineering. 2023;31(4):045001. https://doi.org/10.1088/1361-651X/acc960
25. Wei G., Huang P., Xu C., Liu D., Ju X., Du X., Xing L., Yang Y. Thermophysical property measurements and thermal energy storage capacity analysis of aluminum alloys. Solar Energy. 2016;137:66–72. https://doi.org/10.1016/j.solener.2016.07.054
Review
For citations:
Kuskov K.V., Nepapushev A.A., Moskovskikh D.O. Selective laser melting and functional properties of AlSi10Mg-based aluminum matrix composites with Cu, CuNi, and CuNiFeCo additives. Powder Metallurgy аnd Functional Coatings (Izvestiya Vuzov. Poroshkovaya Metallurgiya i Funktsional'nye Pokrytiya). 2026;20(2):71-83. (In Russ.) https://doi.org/10.17073/1997-308X-2026-2-71-83
Views:
18
JATS XML
Email this article 