Metal matrix composites reinforced by nano-particles are very promising materials, suitable for a large number of applications. These composites consist of a metal matrix filled with nano-particles featuring physical and mechanical properties very different from those of the matrix. The nano-particles can improve the base material in terms of wear resistance, damping properties and mechanical strength. Different kinds of metals, predominantly Al, Mg and Cu, have been employed for the production of composites reinforced by nano-ceramic particles such as carbides, nitrides, oxides as well as carbon nanotubes. The main issue of concern for the synthesis of these materials consists in the low wettability of the reinforcement phase by the molten metal, which does not allow the synthesis by conventional casting methods. Several alternative routes have been presented in literature for the production of nano-composites. This work is aimed at reviewing the most important manufacturing techniques used for the synthesis of bulk metal matrix nanocomposites. Moreover, the strengthening mechanisms responsible for the improvement of mechanical properties of nano-reinforced metal matrix composites have been reviewed and the main potential applications of this new class of materials are envisaged.

An 18-Ni 300 grade maraging steel was processed by selective laser melting and an investigation was carried out on microstructural and mechanical behaviour as a function of aging condition. Owing to the rapid cooling rate, the as-built alloy featured a full potential for precipitate strengthening, without the need of a solution treatment prior to aging. The amount of reversed austenite found in the microstructure increased after aging and revealed to depend on aging temperature and time. Similarly to the corresponding wrought counterpart, also in the selective laser-melted 18-Ni 300 alloy, aging promoted a dramatic increase in strength with respect to the as-built condition and a drop in tensile ductility. No systematic changes were found in tensile properties as a function of measured amount of austenite. It is proposed that the submicrometric structure and the phase distribution inherited by the rapid solidification condition brought by selective laser melting are such that changes in tensile strength and ductility are mainly governed by the effects brought by the strengthening precipitates, whereas the concurrent reversion of the γ-Fe phase in different amounts seems to play a minor role.

The AlSi10Mg alloy was processed by selective laser melting using both hot- and cold-build platforms. The investigation was aimed at defining suitable platform pre-heating and post-process thermal treatment strategies, taking into consideration the peculiar microstructures generated. Microstructural analyses, differential scanning calorimetry, and high-resolution diffraction from synchrotron radiation, showed that in the cold platform as-built condition, the amount of supersaturated Si was higher than in hot platform samples. The best hardness and tensile performance were achieved upon direct aging from cold platform-printed alloys. The hot platform strategy led to a loss in the aging response, since the long processing times spent at high temperature induced a substantial overaging effect, already in the as-built samples. Finally, the standard T6 temper consisting of post-process solution annealing followed by artificial aging, resulted in higher ductility but lower mechanical strength.

Purpose: This paper aims to investigate the processability by selective laser melting (SLM) of materials of potential interest for innovative biodegradable implants, pure Fe and pure Zn. The processability of these materials is evaluated with a more established counterpart in permanent implants, stainless steel. In particular, the processing conditions were studied to reduce porosity due to incomplete fusion of the powder. Design/methodology/approach: In the first phase of the experiments, SLM of AISI 316L was studied through design of experiments method. The study was used to identify the significant parameters in the experimental range and estimate the fluence ranges for pure Fe and pure Zn using the lumped heat capacity model. In the second phase, SLM of pure Fe and pure Zn were studied using estimated fluence ranges. In the final phase, best conditions were characterized for mechanical properties. Findings: The results showed that complete melting of AISI 316L and pure Fe could be readily achieved, whereas laser melting generated a foam-like porous structure in Zn samples. The mechanical properties of laser melt implant materials were compared to as-cast and rolled counterparts. Laser melted AISI 316L showed superior mechanical performance compared to as-cast and rolled material, whereas Fe showed mechanical performance similar to rolled mild steel. Despite 12 per cent apparent porosity, laser melted Zn exhibited superior mechanical properties compared to as-cast and wrought material because of reduced grain size. Originality/value: The paper provides key processing knowledge on the SLM processability of new biodegradable metals, namely, pure Fe, which has been studied sparingly, and pure Zn, on which no previous work is available. The results prefigure the production of new biodegradable metallic implants with superior mechanical properties compared to their polymeric counterparts and with improved degradation rates compared to magnesium alloys, the reference material for biodegradable metals.

The fatigue behaviour of an AlSi10Mg alloy processed by laser powder bed fusion (L-PBF) and subjected to different surface finishing processes was investigated paying special attention to the residual defects on the surface and the dominant fatigue failure mechanisms. Roughness measurements and qualitative surface morphology analysis showed smooth surfaces in the case of vibro-finishing and machining followed by polishing. The fatigue performance did not reveal to be directly related to surface roughness, but residual intrusions left on the finished surfaces. Post-mortem analysis showed single- or multiple-crack nucleation from pores opened on the surface, un-melted powders, or spatters considered as typical L-PBF defects. A fatigue limit of 195 MPa for machined and polished samples was obtained by substantial removal of surface and subsurface defects.