Laser powder bed fusion (LPBFLaser Powder Bed Fusion (LPBF)) is a metal additive manufacturingAdditive manufacturing (AM) technique capable of producing complex and intricate geometries. However, conventional high-strengthStrength wrought aluminium alloysAluminium alloys (e.g., 7xxx and 2xxx series) are not suitable for LPBFLaser Powder Bed Fusion (LPBF) due to volatile alloying elements and hot cracking. Recent research has focused on developing new Al alloysAl alloys specifically for AM by incorporating transition elements such as Fe, Cr, Ti, and others, as Si. These elements offer low solubility and diffusion in Al, promoting intermetallicIntermetallics formation, high-temperature stability, and reduced post-processingProcessing needs. This work presents recent developments in AlFeCrTi and AlFeCrSi alloys tailored for LPBFLaser Powder Bed Fusion (LPBF). While the Si-containing variant exhibits a columnar microstructureMicrostructure, the Ti-containing alloy produces fineFines equiaxed grains. Additionally, both alloys exhibit distinct types of precipitates whose distribution directly influences grain size. In AlFeCrSi, the formation of silicide phases creates a cellular structure within the aluminumAluminum matrix. In contrast, AlFeCrTi features a highly interconnected precipitate network, which defines a fineFines and highly misoriented grain structureGrain structure. These differences influence local strain distribution, analysed using high-resolution digital image correlation (HR-DIC). The findings provide key insights into alloy designAlloy design strategies for enhancing mechanical performance in AM-processed aluminiumAluminium systems.

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Designing Aluminium Alloys for LPBF: Tailoring Microstructure and Performance with Transition Elements

  • Alberto Orozco-Caballero,
  • Farid Bahari-Sambran,
  • Fernando Carreño,
  • Carmen M. Cepeda-Jiménez

摘要

Laser powder bed fusion (LPBFLaser Powder Bed Fusion (LPBF)) is a metal additive manufacturingAdditive manufacturing (AM) technique capable of producing complex and intricate geometries. However, conventional high-strengthStrength wrought aluminium alloysAluminium alloys (e.g., 7xxx and 2xxx series) are not suitable for LPBFLaser Powder Bed Fusion (LPBF) due to volatile alloying elements and hot cracking. Recent research has focused on developing new Al alloysAl alloys specifically for AM by incorporating transition elements such as Fe, Cr, Ti, and others, as Si. These elements offer low solubility and diffusion in Al, promoting intermetallicIntermetallics formation, high-temperature stability, and reduced post-processingProcessing needs. This work presents recent developments in AlFeCrTi and AlFeCrSi alloys tailored for LPBFLaser Powder Bed Fusion (LPBF). While the Si-containing variant exhibits a columnar microstructureMicrostructure, the Ti-containing alloy produces fineFines equiaxed grains. Additionally, both alloys exhibit distinct types of precipitates whose distribution directly influences grain size. In AlFeCrSi, the formation of silicide phases creates a cellular structure within the aluminumAluminum matrix. In contrast, AlFeCrTi features a highly interconnected precipitate network, which defines a fineFines and highly misoriented grain structureGrain structure. These differences influence local strain distribution, analysed using high-resolution digital image correlation (HR-DIC). The findings provide key insights into alloy designAlloy design strategies for enhancing mechanical performance in AM-processed aluminiumAluminium systems.