Uniform distribution of carbon nanotubes (CNTs) in metal matrix during additive manufacturing of nanocomposites is always a challenge since the CNTs tend to aggregate in the molten pool. In this study, Multiwall carbon nanotubes (MWNTs) were separated and distributed uniformly into iron matrix by laser sintering process. MWNTs and iron powders were mixed together by magnetic stir, coated on steel 4140 surface, followed by laser sintering. Due to the fast heating and cooling rate, the CNTs are evenly distributed in the metal matrix. The temperature field was calculated by multiphysics simulation considering size effects, including size dependent melting temperature, thermal conductivity, and heat capacity. The SEM, TEM, and XRD were used to understand the laser sintering of CNT integrated nanocomposites. The results proved the feasibility of this technique to synthesize MWNTS integrated metal matrix nanocomposites. (C) 2014 AIP Publishing LLC
