Effects of direct aging on mechanical properties and microstructure of TiB2/AlSi7Mg alloy fabricated by laser powder bed fusion

The effects of direct aging (DA) on the microstructure and mechanical properties of TiB2/AlSi7Mg alloys fabricated via laser powder bed fusion (LPBF) were systematically investigated. DA significantly improves strength while maintaining satisfactory ductility. Optimal performance is obtained through under-aging (UA) at 150 °C for 4 h, resulting in a yield strength of 361 MPa, tensile strength of 503 MPa, and elongation of 9.1% in the horizontal direction. DA does not substantially alter the grain size or cellular structure but promotes the formation of nanoprecipitates within the α-Al matrix. Specifically, UA induces dot-like and needle-like Si precipitates, whereas over-aging (OA) additionally generates short rod-like β′-Mg1.8Si phases. The strengthening mechanism is attributed to the Hall–Petch effect associated with grain and cell boundaries, and the Orowan mechanism induced by nanoprecipitates. Work-hardening behavior is governed by interactions between dislocations and nanoprecipitates. The OA sample exhibits rapid saturation of work hardening due to a high initial hardening rate and dynamic recovery of dislocations, resulting in limited uniform elongation. In contrast, the UA sample demonstrates a more balanced work hardening response. These findings provide theoretical and experimental validation of DA as an effective post-processing approach aimed at enhancing the performance of LPBF Al-Si-Mg alloys in engineering applications.