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<p>Solidification defects are critical and prevalent issues in the&#xa0;additive manufacturing of high-strength aluminum alloys. In this study, characteristics and formation mechanisms of solidification defects in&#xa0;additively manufactured high-strength 2A14 aluminum alloy were systematically investigated. Intergranular pores and coarse secondary phases appear at the crack tips, and intergranular cracks are formed by pore propagation along grain boundaries. Intergranular secondary phases play a key role in the formation of intergranular solidification defects. Increasing intergranular secondary phase content effectively suppresses the formation of intergranular pores and cracks, thereby significantly reducing the crack density in the&#xa0;2A14 alloy, despite the presence of coarsened columnar grains, a high fraction of columnar grains, strong texture, and a consistently high fraction of high-angle grain boundaries, which are generally considered to increase crack susceptibility. These results suggest that regulating intergranular secondary phases is an effective strategy to eliminate intergranular solidification defects, particularly cracks. The findings provide theoretical support for the design of aluminum alloys for additive manufacturing.</p>

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Intergranular solidification defects in high-strength 2A14 aluminum alloy fabricated by laser additive manufacturing: Role of secondary phases

  • 期刊论文

  • 发表日期：

    2026年1月4日

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  • Tao Liu,
  • Boyun Huang,
  • Zuming Liu,
  • Jiangbin Luo,
  • Yazhou Zhang,
  • Shupeng Ye,
  • Daoyan Jiang,
  • Runxing Zhou,
  • Peicheng Mo

摘要

Solidification defects are critical and prevalent issues in the additive manufacturing of high-strength aluminum alloys. In this study, characteristics and formation mechanisms of solidification defects in additively manufactured high-strength 2A14 aluminum alloy were systematically investigated. Intergranular pores and coarse secondary phases appear at the crack tips, and intergranular cracks are formed by pore propagation along grain boundaries. Intergranular secondary phases play a key role in the formation of intergranular solidification defects. Increasing intergranular secondary phase content effectively suppresses the formation of intergranular pores and cracks, thereby significantly reducing the crack density in the 2A14 alloy, despite the presence of coarsened columnar grains, a high fraction of columnar grains, strong texture, and a consistently high fraction of high-angle grain boundaries, which are generally considered to increase crack susceptibility. These results suggest that regulating intergranular secondary phases is an effective strategy to eliminate intergranular solidification defects, particularly cracks. The findings provide theoretical support for the design of aluminum alloys for additive manufacturing.