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<p>High susceptibility to hydrogen porosity is frequently observed in weld metal (WM) during fusion welding of laser powder bed fusion (L-PBF) AlSi10Mg alloys. In this work, hydrogen porosity in L-PBF AlSi10Mg alloy welded joints were reduced using vacuum pre-weld heat treatment (HT: 300-500 °C) and Er/Zr-modified filler powder during laser metal deposition (LMD) welding. The results indicate that higher HT temperatures more effectively decrease WM porosity. While the&#xa0;HT minimally affects WM microstructure, it fragments eutectic Si networks in the base material (BM) and reduces Si solid solubility in the Al matrix. Er/Zr addition also reduces porosity, promotes densification of eutectic Si networks, refines α-Al cells, and increases Si solubility. The WM with Er/Zr addition consistently exhibits superior hardness compared to those without Er/Zr&#xa0;addition. Pre-weld HT (300-500 °C) reduces the ultimate tensile strength (UTS) of joints but significantly increases elongation (EI) at fracture. The welded&#xa0;joint with 300 °C HT and Er/Zr-modified filler achieve optimal strength-ductility balance. Er/Zr addition crucially modifiesd the WM microstructure and reduces porosity, thereby enhancing UTS. The combined approach of HT and Er/Zr filler effectively mitigates porosity and improves joint properties.</p>

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Reducing Porosity in LPBF-Fabricated AlSi10Mg Weld Metal via Laser Metal Deposition Welding and Heat Treatment

  • 期刊论文

  • 发表日期：

    2025年11月28日

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  • Yingying Liu,
  • Jingchuan Li,
  • Zhaotong Li,
  • Li Cui,
  • Jiutong Qiao,
  • Dingyong He,
  • Qing Cao,
  • Jie Xu

摘要

High susceptibility to hydrogen porosity is frequently observed in weld metal (WM) during fusion welding of laser powder bed fusion (L-PBF) AlSi10Mg alloys. In this work, hydrogen porosity in L-PBF AlSi10Mg alloy welded joints were reduced using vacuum pre-weld heat treatment (HT: 300-500 °C) and Er/Zr-modified filler powder during laser metal deposition (LMD) welding. The results indicate that higher HT temperatures more effectively decrease WM porosity. While the HT minimally affects WM microstructure, it fragments eutectic Si networks in the base material (BM) and reduces Si solid solubility in the Al matrix. Er/Zr addition also reduces porosity, promotes densification of eutectic Si networks, refines α-Al cells, and increases Si solubility. The WM with Er/Zr addition consistently exhibits superior hardness compared to those without Er/Zr addition. Pre-weld HT (300-500 °C) reduces the ultimate tensile strength (UTS) of joints but significantly increases elongation (EI) at fracture. The welded joint with 300 °C HT and Er/Zr-modified filler achieve optimal strength-ductility balance. Er/Zr addition crucially modifiesd the WM microstructure and reduces porosity, thereby enhancing UTS. The combined approach of HT and Er/Zr filler effectively mitigates porosity and improves joint properties.