Microstructure and properties of oxide-reinforced FeCrAl matrix alloy manufactured by selective laser melting

In this work, nano-Y2O3 dispersed FeCrAl powders (NYD-Fe) were used to produce oxide dispersion strengthened (ODS) alloy by selective laser melting (SLM), and their microstructures and properties were investigated in detail by the kinds of characterization techniques. The results indicate that the Y2O3 particles adhered to the surface of FeCrAl powder absorb more laser, thus increasing the laser energy demand. High quality ODS deposits can be obtained at 600mm/s and 180W parameters. The ODS samples deposited by SLM exhibit coarse columnar grains with [001] texture. The Ti-rich nanoparticles and core-shell structured nanoparticles (Y- and O-rich core surrounded by a Ti-rich shell) are observed in ODS alloys. The precipitation formation of core-shell structured nanoparticles involves ball milling amorphization and dissolution reprecipitation. The ODS-180 alloy exhibits a higher ductility compared to FeCrAl-180 alloy, which is caused by the cellular structure with high density dislocations and the nano-sized precipitates inhibit the dislocation motion. The wear rate of the ODS-180 alloy is 51% lower than that of FeCrAl-180 alloy, which is mainly ascribed to the hardness and interface oxide layer resulting from its specific microstructural features.