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<p>To address the performance limitations arising from inherent defects in the laser powder bed fusion (L-PBF) process, this study proposes and demonstrates a simulation-driven alloy design framework. First, a high-fidelity multiphysics model encompassing melt pool dynamics, temperature–flow coupling, and solidification behaviour was employed to predict the printability of a newly designed aluminium–nickel (Al–Ni) alloy composition microalloyed with 0.7% scandium (Sc). Guided by simulations, the alloy was fabricated in a single experimental run using simulated process parameters. Experimental results validated the framework’s efficacy: the scandium-modified aluminium-nickel alloy exhibited outstanding tensile strength (440&#xa0;MPa) and yield strength (321&#xa0;MPa) at room temperature, maintaining high levels at 200&#xa0;°C (300&#xa0;MPa and 245&#xa0;MPa respectively). Microstructural analysis revealed that scandium addition formed coherent L1₂-Al₃Sc nanoparticles. These particles acted as effective heterogenous nucleation sites, promoting the transformation of columnar crystals into equiaxed grains while providing dispersion strengthening. Consequently, this study not only proposes a highly promising high-temperature aluminium alloy suitable for L-PBF processes but also validates a predictable, simulation-guided approach that accelerates the development of customised additive manufacturing materials.</p>

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Achieving high-temperature strength in additively manufactured Al–Ni alloys through Sc microalloying: a multiphysics simulation and experimental study

  • 期刊论文

  • 发表日期：

    2026年5月23日

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  • Jian Li,
  • Yaoxin Huang,
  • Jianfeng Wen,
  • Peng Zou,
  • Wei Guo,
  • Ting Ye,
  • Zhewei Jiang,
  • Pengwan Zhu

摘要

To address the performance limitations arising from inherent defects in the laser powder bed fusion (L-PBF) process, this study proposes and demonstrates a simulation-driven alloy design framework. First, a high-fidelity multiphysics model encompassing melt pool dynamics, temperature–flow coupling, and solidification behaviour was employed to predict the printability of a newly designed aluminium–nickel (Al–Ni) alloy composition microalloyed with 0.7% scandium (Sc). Guided by simulations, the alloy was fabricated in a single experimental run using simulated process parameters. Experimental results validated the framework’s efficacy: the scandium-modified aluminium-nickel alloy exhibited outstanding tensile strength (440 MPa) and yield strength (321 MPa) at room temperature, maintaining high levels at 200 °C (300 MPa and 245 MPa respectively). Microstructural analysis revealed that scandium addition formed coherent L1₂-Al₃Sc nanoparticles. These particles acted as effective heterogenous nucleation sites, promoting the transformation of columnar crystals into equiaxed grains while providing dispersion strengthening. Consequently, this study not only proposes a highly promising high-temperature aluminium alloy suitable for L-PBF processes but also validates a predictable, simulation-guided approach that accelerates the development of customised additive manufacturing materials.