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We report a eutecticEutectic Al–Fe–Mg–Zr alloy produced by laser powder bed fusionLaser Powder Bed Fusion (LPBF) that achieves crack-free fabrication with 99.8% relative density and an ultrafine, cellular–lamellar microstructureMicrostructure. Direct aging at 400 °C for 4 h delivers peak room-temperature strengthStrength (yield strengthStrength (YS) of 392.9 MPa, ultimate tensile strengthTensile strength (UTS) of 415.8 MPa, and elongation of 8.5%) owing to a dual mechanism: load transferLoad transfer from a dense dispersion of Fe-rich intermetallicsIntermetallics and precipitation strengthening from coherent L12–Al3Zr nanoparticles. Multiscale microstructureMicrostructure characterizationCharacterization shows that the rapidly solidified Al6Fe formed in the as-built state evolves toward thermodynamically stable Al13Fe4 during aging, while Al3Zr remains coherent. After 400 °C annealingAnnealing for 100 h, coarsening of Al–Fe dispersoidsDispersoids increases interparticle spacing and reduces the load-transfer contribution, but the slow-coarsening, coherent Al3Zr dispersion stabilizes the microstructureMicrostructure and supports strengthStrength retention (YS of 309.7 MPa and UTS of 354.6 MPa). The results demonstrate a process-compatible pathway to combine high strengthStrength with thermal stabilityThermal stability in LPBFLaser Powder Bed Fusion (LPBF) aluminum alloysAluminum alloy through coordinated control of intermetallicIntermetallics dispersoidsDispersoids and coherent nanoprecipitates.

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Microstructure Evolution and Heat Resistance of an Al–Fe–Mg–Zr Eutectic Alloy Fabricated by Laser Powder Bed Fusion

  • 会议论文

  • 发表日期：

    2026年

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  • Feng Li,
  • Bart J. Kooi,
  • Yutao Pei

摘要

We report a eutecticEutectic Al–Fe–Mg–Zr alloy produced by laser powder bed fusionLaser Powder Bed Fusion (LPBF) that achieves crack-free fabrication with 99.8% relative density and an ultrafine, cellular–lamellar microstructureMicrostructure. Direct aging at 400 °C for 4 h delivers peak room-temperature strengthStrength (yield strengthStrength (YS) of 392.9 MPa, ultimate tensile strengthTensile strength (UTS) of 415.8 MPa, and elongation of 8.5%) owing to a dual mechanism: load transferLoad transfer from a dense dispersion of Fe-rich intermetallicsIntermetallics and precipitation strengthening from coherent L12–Al3Zr nanoparticles. Multiscale microstructureMicrostructure characterizationCharacterization shows that the rapidly solidified Al6Fe formed in the as-built state evolves toward thermodynamically stable Al13Fe4 during aging, while Al3Zr remains coherent. After 400 °C annealingAnnealing for 100 h, coarsening of Al–Fe dispersoidsDispersoids increases interparticle spacing and reduces the load-transfer contribution, but the slow-coarsening, coherent Al3Zr dispersion stabilizes the microstructureMicrostructure and supports strengthStrength retention (YS of 309.7 MPa and UTS of 354.6 MPa). The results demonstrate a process-compatible pathway to combine high strengthStrength with thermal stabilityThermal stability in LPBFLaser Powder Bed Fusion (LPBF) aluminum alloysAluminum alloy through coordinated control of intermetallicIntermetallics dispersoidsDispersoids and coherent nanoprecipitates.