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The strength for this material system was characterised and compared to predictions from theoretical analyses based on the elastic constants of individual phases and the homogeneous composites of each phase and the homogeneous mixture of each phase. Combinations of large and small binary subluminousAll authors Richard A. Michi, Alex Plotkowski, Amit Shyam, Ryan R. Dehoff & Sudarsanam Suresh Babu Published online:16 July 2021Figure 5. strengthening effect by Co, Cr, Zr, W, Mo, Ta, as well as La on FbSi1-based polymeric AM All authors Richard A. Michi, Alex Plotkowski, Amit Shyam, Ryan R. Dehoff & Sudarsanam Suresh Babu Published online:16 July 2021Figure 6. strengthening effect by Co, Cr, Zr, W, Mo, Ta, as well as La on Am3As-based polymeric AM All authors Richard A. Michi, Alex Plotkowski, Amit Shyam, Ryan R.Although carbon additives can contribute to nucleation in Al alloys, these additions can also contribute to additional porosity by forming a non-reactive layer that grows during DED [ 164166 ]. The formation of a thermodynamic metastable Al2CO3 during DED is typically an indicator of porosity [ 164167 ]. However, it should be noted that the exact phase is not the only key factor and a wide range of solid aluminum carbide compounds can exist, including peritectic alloys like Al6SiC2 and AlFeC, and oxide alloys like AlCuOx. Although the effect of carbon additions on nucleation sites in Al is not fully understood, it is thought that grain refinement of Al is partly due to the addition of carbon, forming an Al-based carbide. The Al-based carbide decomposes to form sub-micron dispersed nano-sized Al2O3 and/or Al6C flakes during DED, reducing the free-energy of formation and increasing the nucleation density of Al. For instance, a study on 5% wt-% carbon modified Al6061 alloy showed an increased number of equiaxed grains, with the major grain size reduction observed parallel to the build direction [ 165 ]. The addition of 0.5% Si and 0.5% TiC to Al6061 significantly reduced the percentage of equiaxed grains, with only minor changes observed parallel to the build direction [ 165 ]. Carbon enriched Al-Ti mixed powders containing 2 wt-% TiC, 0.5 wt-% Si and 0.5 wt-% Mg allowed the nucleation of Al grains at an average size of 0.9m, with average grain size of 0.4m observed parallel to the build direction [ 166 ]. The main effect is thought to be due to nano-sized Al2Ti dispersed within the carbides. It is likely that additions of carbon, silicon and titanium are promoting nucleation sites in both pure and alloyed Al.
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