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Iron is unavoidable but detrimental in Al alloyAl alloy recyclingRecycling as it forms plate- or needle-like Fe-containing intermetallicIntermetallic particles (FIMPs) in the alloy during castingCasting. A more accurate understanding of Fe effects on microstructural change and performance is critical to the management and separation of recyclingRecycling feedstocks. This study investigates the effect of Fe contents in the second phase particles of Al-Mn-Fe-Si alloys fabricated by laser directed energy deposition (DED) additive manufacturingAdditive manufacturing (AM). Four Al–Mn–Fe–Si alloys featuring different levels of Fe were deposited by DED. The heated substrate with different temperature was applied during the fabrication to adjust the solidificationSolidification cooling ratesCooling rate. The results suggest that higher Fe content in the alloy would induce the formation of Al13(Fe, Mn)4 particle. However, the high cooling rateCooling rate led to the finer size Al13(Fe, Mn)4 particles with the lower aspect ratio, while needle-like Al13(Fe, Mn)4 particles were produced by slow cooling rateCooling rate. Besides, the high cooling rateCooling rate benefitted the formation of fine size α-Al(Fe, Mn)–Si. Increasing the cooling rateCooling rate can enhance the Fe-toleranceFe tolerance in the alloy without forming needle-likeHigh-throughput method particles.

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Effect of Fe on Al–Mn–Fe–Si Alloys Made by Laser Additive Manufacturing

  • 会议论文

  • 发表日期：

    2025年

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  • Qingyu Pan,
  • Monica Kapoor,
  • John Carsley,
  • Xiaoyuan Lou

摘要

Iron is unavoidable but detrimental in Al alloyAl alloy recyclingRecycling as it forms plate- or needle-like Fe-containing intermetallicIntermetallic particles (FIMPs) in the alloy during castingCasting. A more accurate understanding of Fe effects on microstructural change and performance is critical to the management and separation of recyclingRecycling feedstocks. This study investigates the effect of Fe contents in the second phase particles of Al-Mn-Fe-Si alloys fabricated by laser directed energy deposition (DED) additive manufacturingAdditive manufacturing (AM). Four Al–Mn–Fe–Si alloys featuring different levels of Fe were deposited by DED. The heated substrate with different temperature was applied during the fabrication to adjust the solidificationSolidification cooling ratesCooling rate. The results suggest that higher Fe content in the alloy would induce the formation of Al13(Fe, Mn)4 particle. However, the high cooling rateCooling rate led to the finer size Al13(Fe, Mn)4 particles with the lower aspect ratio, while needle-like Al13(Fe, Mn)4 particles were produced by slow cooling rateCooling rate. Besides, the high cooling rateCooling rate benefitted the formation of fine size α-Al(Fe, Mn)–Si. Increasing the cooling rateCooling rate can enhance the Fe-toleranceFe tolerance in the alloy without forming needle-likeHigh-throughput method particles.