Phase transformation induced expansion for residual stress relief in laser additive manufacturing metal matrix diamond composites

Yuan Gao; Wei Zhang; Yingbo Peng; Qingyuan Ma; Yuxuan Chen; Jiarong Chen; Xiaohan Du; Yongjian Fang; Yali Zhang; Yong Liu; Shoufeng Yang

doi:10.1016/j.addma.2025.104883

Phase transformation induced expansion for residual stress relief in laser additive manufacturing metal matrix diamond composites

Yuan Gao, Wei Zhang^*, Yingbo Peng^*, Qingyuan Ma, Yuxuan Chen, Jiarong Chen, Xiaohan Du, Yongjian Fang^*, Yali Zhang, Yong Liu, Shoufeng Yang

^*Corresponding author for this work

Department of Systems Engineering

Research output: Journal Publications and Reviews › RGC 21 - Publication in refereed journal › peer-review

2 Citations (Scopus)

Abstract

While laser powder bed fusion (LPBF) has emerged as a transformative approach for fabricating geometrically intricate metal matrix-diamond composites, the interfacial integrity of these components is critically undermined by residual stress originating from rapid thermal cycling and severe thermal expansion mismatch between diamond reinforcements and metallic binders. Existing mitigation strategies—including process parameter optimization, ductile phase incorporation, and graded CTE transition layers—fail to eliminate interfacial microcracks due to inherent limitations in thermal strain compensation. Herein, we propose a phase-transformation-driven stress-relief strategy by engineering a W/Co bilayer coating on diamond particles within a CuSn10 matrix. The tungsten interlayer ensures interfacial integrity through carbide bonding and thermal buffering, while the cobalt overlayer exploits HCP→FCC phase transformation during LPBF thermal cycling to generate compensatory volumetric expansion, effectively counteracting thermal contraction-induced residual stress. The W-Co coated diamond/CuSn10 composite achieved a bending strength of 159 MPa (90 % higher than Ti-Cu coated counterparts) and a friction coefficient of 0.25, with complete suppression of interfacial cracking under cyclic wear. Multiscale characterization revealed that Co-induced twinning and dynamic recrystallization synergistically enhanced interfacial toughness, while molecular dynamics simulations quantitatively validated the stress-neutralization mechanism through lattice mismatch analysis. This work establishes a transformative "expansion-compensation" paradigm for residual stress regulation in MMCs, advancing the design of crack-resistant diamond composites for high-stress additive manufacturing applications.

© 2025 Elsevier B.V. All rights are reserved, including those for text and data mining, AI training, and similar technologies.

Original language	English
Article number	104883
Journal	Additive Manufacturing
Volume	109
DOIs	https://doi.org/10.1016/j.addma.2025.104883
Publication status	Published - Jul 2025

Funding

The authors are grateful for the financial support of the Ministry of Science and Technology of the People's Republic of China (Grant No. 2021YFB3701800), the National Natural Science Foundation of China (Grant No. 52474395), the Department of Science and Technology of Hunan Province (Grant No. 2023JJ50026), the Key Research and Development Special Project of Henan Provincial Program of China (Grant No. 231111231200).

Research Keywords

Diamond composites
Laser additive manufacturing
Phase transformation-induced expansion
Interfacial stress relief
Mechanical properties

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This output contributes to the following UN Sustainable Development Goals (SDGs)

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title = "Phase transformation induced expansion for residual stress relief in laser additive manufacturing metal matrix diamond composites",

abstract = "While laser powder bed fusion (LPBF) has emerged as a transformative approach for fabricating geometrically intricate metal matrix-diamond composites, the interfacial integrity of these components is critically undermined by residual stress originating from rapid thermal cycling and severe thermal expansion mismatch between diamond reinforcements and metallic binders. Existing mitigation strategies—including process parameter optimization, ductile phase incorporation, and graded CTE transition layers—fail to eliminate interfacial microcracks due to inherent limitations in thermal strain compensation. Herein, we propose a phase-transformation-driven stress-relief strategy by engineering a W/Co bilayer coating on diamond particles within a CuSn10 matrix. The tungsten interlayer ensures interfacial integrity through carbide bonding and thermal buffering, while the cobalt overlayer exploits HCP→FCC phase transformation during LPBF thermal cycling to generate compensatory volumetric expansion, effectively counteracting thermal contraction-induced residual stress. The W-Co coated diamond/CuSn10 composite achieved a bending strength of 159 MPa (90 % higher than Ti-Cu coated counterparts) and a friction coefficient of 0.25, with complete suppression of interfacial cracking under cyclic wear. Multiscale characterization revealed that Co-induced twinning and dynamic recrystallization synergistically enhanced interfacial toughness, while molecular dynamics simulations quantitatively validated the stress-neutralization mechanism through lattice mismatch analysis. This work establishes a transformative {"}expansion-compensation{"} paradigm for residual stress regulation in MMCs, advancing the design of crack-resistant diamond composites for high-stress additive manufacturing applications.{\textcopyright} 2025 Elsevier B.V. All rights are reserved, including those for text and data mining, AI training, and similar technologies. ",

keywords = "Diamond composites, Laser additive manufacturing, Phase transformation-induced expansion, Interfacial stress relief, Mechanical properties",

author = "Yuan Gao and Wei Zhang and Yingbo Peng and Qingyuan Ma and Yuxuan Chen and Jiarong Chen and Xiaohan Du and Yongjian Fang and Yali Zhang and Yong Liu and Shoufeng Yang",

year = "2025",

month = jul,

doi = "10.1016/j.addma.2025.104883",

language = "English",

volume = "109",

journal = "Additive Manufacturing",

issn = "2214-8604",

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TY - JOUR

T1 - Phase transformation induced expansion for residual stress relief in laser additive manufacturing metal matrix diamond composites

AU - Gao, Yuan

AU - Zhang, Wei

AU - Peng, Yingbo

AU - Ma, Qingyuan

AU - Chen, Yuxuan

AU - Chen, Jiarong

AU - Du, Xiaohan

AU - Fang, Yongjian

AU - Zhang, Yali

AU - Liu, Yong

AU - Yang, Shoufeng

PY - 2025/7

Y1 - 2025/7

N2 - While laser powder bed fusion (LPBF) has emerged as a transformative approach for fabricating geometrically intricate metal matrix-diamond composites, the interfacial integrity of these components is critically undermined by residual stress originating from rapid thermal cycling and severe thermal expansion mismatch between diamond reinforcements and metallic binders. Existing mitigation strategies—including process parameter optimization, ductile phase incorporation, and graded CTE transition layers—fail to eliminate interfacial microcracks due to inherent limitations in thermal strain compensation. Herein, we propose a phase-transformation-driven stress-relief strategy by engineering a W/Co bilayer coating on diamond particles within a CuSn10 matrix. The tungsten interlayer ensures interfacial integrity through carbide bonding and thermal buffering, while the cobalt overlayer exploits HCP→FCC phase transformation during LPBF thermal cycling to generate compensatory volumetric expansion, effectively counteracting thermal contraction-induced residual stress. The W-Co coated diamond/CuSn10 composite achieved a bending strength of 159 MPa (90 % higher than Ti-Cu coated counterparts) and a friction coefficient of 0.25, with complete suppression of interfacial cracking under cyclic wear. Multiscale characterization revealed that Co-induced twinning and dynamic recrystallization synergistically enhanced interfacial toughness, while molecular dynamics simulations quantitatively validated the stress-neutralization mechanism through lattice mismatch analysis. This work establishes a transformative "expansion-compensation" paradigm for residual stress regulation in MMCs, advancing the design of crack-resistant diamond composites for high-stress additive manufacturing applications.© 2025 Elsevier B.V. All rights are reserved, including those for text and data mining, AI training, and similar technologies.

AB - While laser powder bed fusion (LPBF) has emerged as a transformative approach for fabricating geometrically intricate metal matrix-diamond composites, the interfacial integrity of these components is critically undermined by residual stress originating from rapid thermal cycling and severe thermal expansion mismatch between diamond reinforcements and metallic binders. Existing mitigation strategies—including process parameter optimization, ductile phase incorporation, and graded CTE transition layers—fail to eliminate interfacial microcracks due to inherent limitations in thermal strain compensation. Herein, we propose a phase-transformation-driven stress-relief strategy by engineering a W/Co bilayer coating on diamond particles within a CuSn10 matrix. The tungsten interlayer ensures interfacial integrity through carbide bonding and thermal buffering, while the cobalt overlayer exploits HCP→FCC phase transformation during LPBF thermal cycling to generate compensatory volumetric expansion, effectively counteracting thermal contraction-induced residual stress. The W-Co coated diamond/CuSn10 composite achieved a bending strength of 159 MPa (90 % higher than Ti-Cu coated counterparts) and a friction coefficient of 0.25, with complete suppression of interfacial cracking under cyclic wear. Multiscale characterization revealed that Co-induced twinning and dynamic recrystallization synergistically enhanced interfacial toughness, while molecular dynamics simulations quantitatively validated the stress-neutralization mechanism through lattice mismatch analysis. This work establishes a transformative "expansion-compensation" paradigm for residual stress regulation in MMCs, advancing the design of crack-resistant diamond composites for high-stress additive manufacturing applications.© 2025 Elsevier B.V. All rights are reserved, including those for text and data mining, AI training, and similar technologies.

KW - Diamond composites

KW - Laser additive manufacturing

KW - Phase transformation-induced expansion

KW - Interfacial stress relief

KW - Mechanical properties

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U2 - 10.1016/j.addma.2025.104883

DO - 10.1016/j.addma.2025.104883

M3 - RGC 21 - Publication in refereed journal

SN - 2214-8604

VL - 109

JO - Additive Manufacturing

JF - Additive Manufacturing

M1 - 104883

ER -

Phase transformation induced expansion for residual stress relief in laser additive manufacturing metal matrix diamond composites

Abstract

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Research Keywords

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