In-situ formation of ceramic layer on Mo-based composites via laser powder bed fusion

Poor oxidation resistance is a longstanding disadvantage of Mo-based materials for ultrahigh-temperature applications. In this study, we developed a facile strategy for depositing an in-situ ceramic layer on the surface of Mo-based composites via laser powder bed fusion (L-PBF) using Mo-based alloy powders covered with uniform Al₂O₃ nanoparticles and bridged by functionalized carbon nanotubes. The surface layer consisted of an α-Al₂O₃ matrix with a dispersed TiC phase and had a controllable thickness. The formation mechanism of this layer was investigated systematically through single-track observations and finite-element simulation. Moreover, the increased nanohardness can be attributed to the uniformly dispersed, intimately contacted ceramic nanoparticles in the matrix. The results indicated the multifunctionality of L-PBF-processed metallic parts, introducing the possibility of fabricating advanced ultrahigh-temperature materials.