The premature failure of components due to poor inter-particle bonding is the most critical issue in cold spray (CS) additive manufacturing. Herein, a hybrid strategy combining gas-atomization (involving in-situ reaction), CS, and post-friction stir processing was proposed to design a nano-TiB₂/AlSi10Mg composite. Multiscale characterization in terms of X-ray diffraction and scanning and transmission electron microscopy was conducted to track microstructure evolution for better understanding the mechanisms determining mechanical performance of the produced composites. The results showed simultaneous improvement in both ultimate tensile strength (365 ± 35 MPa) and ductility (16.0 ± 1.2%), which represents a breakthrough. The strengthening and toughing mechanisms were attributed to the fine matrix grains with the significantly improved metallurgical inter-particle bonding, and the uniformly distributed TiB₂ nanoparticles as reinforcement that was strongly bonded with the matrix (i.e. the formation of semi-coherent TiB₂/Al interface). This study provides new guidance for hybrid additive manufacturing of metal matrix composites with high performance.

在冷喷涂（CS）增材制造中，由于不良的粒子间粘合而导致的组件过早失效是最关键的问题。在本文中，提出了一种结合气体雾化（涉及原位反应），CS和摩擦后搅拌处理的混合策略来设计纳米TiB _2。/ AlSi10Mg复合材料。进行了X射线衍射，扫描和透射电子显微镜的多尺度表征，以追踪微观结构的演变，以更好地了解决定所生产复合材料机械性能的机理。结果表明，极限抗拉强度（365±35 MPa）和延展性（16.0±1.2％）同时得到改善，这是一个突破。强化和增韧机制归因于具有明显改善的冶金颗粒间键合的精细基体晶粒，以及与基体牢固键合的均匀分布的TiB ₂纳米颗粒作为增强物（即半粘合TiB ₂的形成）/ Al接口）。该研究为高性能的金属基复合材料的混合增材制造提供了新的指导。