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<p>Due to widespread use in the aerospace, automotive, marine, thermal control, and turbomachinery sectors, aluminum alloys are a primary focus of laser powder bed fusion (L-PBF) research. While alloying elements such as Zn, Mg, Si, and Cu are common, Al-Sn alloys (typically used in plain bearing applications) remain under-investigated as L-PBF feedstock. This study examines the printability and mechanical properties of a novel Al-5.12Sn-1.95Cu-0.83Ni alloy. A print parameterization study of the new material covering a broad range of volumetric energy densities was completed and resulted in a maximum relative density of 96.6% (as compared to the maximum theoretical density) at a volumetric energy density of 54.3 <InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(\:\text{J}\bullet\:{\text{m}\text{m}}^{-3}\)</EquationSource> </InlineEquation>. Like other reports of L-PBF manufactured Al-Sn alloys, micro-cracks were observed in all samples produced in the parametrization study, though crack density varied significantly with volumetric energy density. Compression tests revealed an as-printed yield strength nearly 90% higher than conventional cast Al-Sn alloys for the densest sample. Micro-hardness test results concluded that the L-PBF manufactured Al-Sn-Cu-Ni alloy produced hardness values that were comparable to heat treated accumulative roll bonded manufactured Al-Sn alloy. Lastly, thermal expansion tests revealed an elevated coefficient of thermal expansion at approximately 47% higher than similar wrought alloys such as Al 850. The findings of this study further demonstrate that Al-Sn alloys can be processed by L-PBF, revealing the potential of additive manufacturing to enable new materials and designs aimed at improving the effectiveness of Al-Sn components.</p>

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Process parameter investigation and mechanical characterization of an Al-Sn-Cu-Ni alloy manufactured by laser powder bed fusion

  • 期刊论文

  • 发表日期：

    2026年6月17日

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  • Isaiah Yasko,
  • Ian Switzer,
  • Muhammad Ali,
  • Rick Walker

摘要

Due to widespread use in the aerospace, automotive, marine, thermal control, and turbomachinery sectors, aluminum alloys are a primary focus of laser powder bed fusion (L-PBF) research. While alloying elements such as Zn, Mg, Si, and Cu are common, Al-Sn alloys (typically used in plain bearing applications) remain under-investigated as L-PBF feedstock. This study examines the printability and mechanical properties of a novel Al-5.12Sn-1.95Cu-0.83Ni alloy. A print parameterization study of the new material covering a broad range of volumetric energy densities was completed and resulted in a maximum relative density of 96.6% (as compared to the maximum theoretical density) at a volumetric energy density of 54.3 \(\:\text{J}\bullet\:{\text{m}\text{m}}^{-3}\) . Like other reports of L-PBF manufactured Al-Sn alloys, micro-cracks were observed in all samples produced in the parametrization study, though crack density varied significantly with volumetric energy density. Compression tests revealed an as-printed yield strength nearly 90% higher than conventional cast Al-Sn alloys for the densest sample. Micro-hardness test results concluded that the L-PBF manufactured Al-Sn-Cu-Ni alloy produced hardness values that were comparable to heat treated accumulative roll bonded manufactured Al-Sn alloy. Lastly, thermal expansion tests revealed an elevated coefficient of thermal expansion at approximately 47% higher than similar wrought alloys such as Al 850. The findings of this study further demonstrate that Al-Sn alloys can be processed by L-PBF, revealing the potential of additive manufacturing to enable new materials and designs aimed at improving the effectiveness of Al-Sn components.