Process Optimization, Microstructure and Properties of Laser-deposited High-content SiCp Reinforced Al-matrix Composite Coatings

CHI Yiming; WANG Ke; QIAN Dahu; XIANG Dawei; FAN Yajun; YAO Zhehe; YAO Jianhua

doi:10.16490/j.cnki.issn.1001-3660.2026.14.008

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Surface Technology ›› 2026, Vol. 55 ›› Issue (14) : 89-101. DOI: 10.16490/j.cnki.issn.1001-3660.2026.14.008

Process Optimization, Microstructure and Properties of Laser-deposited High-content SiCp Reinforced Al-matrix Composite Coatings

CHI Yiming, WANG Ke, QIAN Dahu, XIANG Dawei, FAN Yajun, YAO Zhehe, YAO Jianhua^*

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Abstract

To address the problems of unstable forming and non-uniform particle distribution commonly encountered during laser deposition of high-content SiCp reinforced Al-matrix composites, the effects of laser power, scanning speed, and overlap offset distance on forming quality and SiCp distribution are systematically investigated. Under optimized processing parameters, SiCp/AlSi10Mg powders are employed to fabricate SiCp/Al composite coatings with different SiCp contents. The interfacial reaction mechanism of SiCp/Al, as well as the microstructure, hardness, and wear resistance of the coatings with varying SiCp contents, are studied.
A planetary ball mill (QM-3SP4) is used to mix the SiCp and AlSi10Mg powders. The ball milling is conducted for 2 h with a ball-to-powder weight ratio of 2∶1 at a rotational speed of 300 rpm, with alternating forward and reverse rotation. The deposited layers are fabricated on a 7075 aluminum alloy substrate using a DAC4000 semiconductor laser with a coaxial powder-feeding system, and the entire deposition process is conducted under a high-purity argon atmosphere. The cross-sectional microstructure and chemical composition of the deposited layers are analyzed by scanning electron microscopy (SEM, ZEISS EVO18) equipped with energy-dispersive spectroscopy (EDS). The phase composition of the deposited layers is characterized using X-ray diffraction (XRD, D/max-Ultima IV). The hardness of the deposited layers is measured using a KLA-G200 nanoindentation tester with a Poisson's ratio of 0.3 and a maximum indentation depth of 2 000 nm. The room-temperature wear performance is evaluated using an MMQ-02G friction and wear tester with a GCr15 steel ball as the counter part under a normal load of 15 N, a rotational speed of 100 r/min, and a wear duration of 30 min. After the wear tests, the three-dimensional surface morphology and two-dimensional cross-sectional profiles of the wear tracks are characterized by laser confocal microscope (CLSM, VK-X1000), and the microstructure of the worn surface was further examined by SEM (ZEISS EVO18).
With a laser power of 2 000 W, a scanning speed of 15 mm/s, and an overlap offset distance of 2.1 mm, a composite coating with a smooth surface, dense microstructure, and uniform SiCp distribution is obtained. Under the optimized parameters, SiCp/AlSi10Mg composite coatings with SiCp contents of approximately 8vol.%-20vol.% are successfully fabricated. The microstructure consists of uniformly dispersed SiCp, a network-like Al-Si eutectic matrix, and a small amount of Al₄C₃. During laser deposition process, the interfacial reaction characteristics between SiCp and molten Al in the molten pool are determined by both direct interfacial reaction and dissolution-precipitation mechanisms. With increasing SiCp content, the average size of SiCp gradually decreases, while the needle-like Al₄C₃ increases in both size and quantity, indicating enhanced SiCp/Al interfacial reactions. The hardness of the deposited coatings increases from 1.475 GPa to approximately 1.685 GPa, and the elastic modulus increases from 86.39 GPa to 94.769 GPa. The well-bonded interface between the uniformly dispersed SiCp and the Al alloy matrix effectively improves the load-bearing capacity of the coating, leading to a significant enhancement in wear resistance. As the SiCp content in the deposited coatings increases, the wear rate declines from 1 325.891 µm³/(N·mm) to 481.552 µm/(N·mm), demonstrating a significant improvement in wear resistance.

Key words

SiCp/Al composites / laser deposition / SiCp/Al interfacial reaction / wear resistance / wear mechanism

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CHI Yiming, WANG Ke, QIAN Dahu, XIANG Dawei, FAN Yajun, YAO Zhehe, YAO Jianhua. Process Optimization, Microstructure and Properties of Laser-deposited High-content SiCp Reinforced Al-matrix Composite Coatings[J]. Surface Technology. 2026, 55(14): 89-101

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Funding

General Program of the National Natural Science Foundation of China (52575461); Exploratory Program of the Natural Science Foundation of Zhejiang Province (LY24E050008); Project Supported by the Fundamental Research Funds for the Provincial Universities of Zhejiang (RF-A2023008)