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<p>The processing of the high-strength AA2024 alloy using the laser powder bed fusion technique is significantly constrained by two factors: its hot-crack sensitivity and thermal reflective properties. The objective of this work is to investigate and establish the inherent limits of processability of AA2024 alloy through the determination of a map of trade-off between densification and defect generation. The current investigation involves the evaluation of a 27-set parametric matrix comprising of variations in laser power levels (100–200&#xa0;W), scan speeds, and hatch spacings, which relate the stability of melt pools to porosity and material properties. Even though volumetric energy density was used as a screening tool, this study illustrates its constraints by observing different defect morphology characteristics despite using parameters with same VED values, thereby revealing that VED is not sufficient in characterizing melt pool behavior. The study shows a clear trend with regard to the transition from lack of fusion porosity defects with low VED values (&lt; 100&#xa0;J/mm<sup>3</sup>) to excessive thermal stress defects associated with higher values (&gt; 170&#xa0;J/mm<sup>3</sup>) with density approaching near full value (99.8%). This research provides a complete defect mapping for AA2024 where the ‘sweet spot’ of processability is determined but also illustrates that even though optimization of processing parameters alone will not address the metallurgical constraints of the alloy.</p>

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Processability window and defect map for LPBF of AA2024: limits of volumetric energy density

  • 期刊论文

  • 发表日期：

    2026年7月28日

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  • Temel Varol,
  • Hüseyin Can Aksa,
  • Serhatcan Berk Akçay,
  • Mahmoud Ebrahimi,
  • Murat Beder,
  • Onur Güler,
  • Mücahit Kocaman

摘要

The processing of the high-strength AA2024 alloy using the laser powder bed fusion technique is significantly constrained by two factors: its hot-crack sensitivity and thermal reflective properties. The objective of this work is to investigate and establish the inherent limits of processability of AA2024 alloy through the determination of a map of trade-off between densification and defect generation. The current investigation involves the evaluation of a 27-set parametric matrix comprising of variations in laser power levels (100–200 W), scan speeds, and hatch spacings, which relate the stability of melt pools to porosity and material properties. Even though volumetric energy density was used as a screening tool, this study illustrates its constraints by observing different defect morphology characteristics despite using parameters with same VED values, thereby revealing that VED is not sufficient in characterizing melt pool behavior. The study shows a clear trend with regard to the transition from lack of fusion porosity defects with low VED values (< 100 J/mm3) to excessive thermal stress defects associated with higher values (> 170 J/mm3) with density approaching near full value (99.8%). This research provides a complete defect mapping for AA2024 where the ‘sweet spot’ of processability is determined but also illustrates that even though optimization of processing parameters alone will not address the metallurgical constraints of the alloy.