The latest development of Sc-strengthened aluminium alloys by laser powder bed fusion

In this paper, the cracking of Al-Mn-Mg-Sc-Zr alloys prepared by selective laser melting (SLM) was comprehensively explored and the influence of process parameters on the generation and propagation of cracks was deeply studied. It was found that the higher laser power and volume energy density will lead to a decrease in the relative density of the material. The lower laser power or volume energy density will lead to cracking of the alloy. The microstructure analysis indicated that plenty of manganese-rich second phases precipitated at the bottom of the melt pool, which increased the tendency of cracking occurred at the bottom of the melt pool. Through the optimization of the process parameters, the SLM forming process parameters of the Al-5.22Mn-1.16Mg-0.81Sc-0.46Zr alloy are successfully obtained, and the crack-free tensile samples are prepared. The microstructure and mechanical properties of the as-deposited aluminum-manganese alloy is analyzed. The bottom and inside of the melt pool are equiaxed grains. The size of the equiaxial grains at the bottom of the melt pool is less than 2 μm, and the coarse equiaxial grains inside the melt pool are approximately 5 μm. As-deposited alloy has a room temperature tensile strength of 455.2 ± 0.7 MPa and elongation of 15.4 ± 0.3%. This study provides guidance for selective laser melting forming of high-strength aluminum-manganese alloy parts, and promotes the industrial production of high-strength aluminum alloy near net forming complex parts.

https://www.mdpi.com/2073-4352/12/4/565/pdf?version=1650269891

Cracking Behavior, Microstructure and Properties of Selective Laser Melted Al-Mn-Mg-Sc-Zr Alloy

Due to its lightweight, high strength, good machinability, and low cost, aluminum alloy has been widely used in fields such as aerospace, automotive, electronics, and construction. Traditional manufacturing processes for aluminum alloys often suffer from low material utilization, complex procedures, and long manufacturing cycles. Therefore, more and more scholars are turning their attention to the laser powder bed fusion (LPBF) process for aluminum alloys, which has the advantages of high material utilization, good formability for complex structures, and short manufacturing cycles. However, the widespread promotion and application of LPBF aluminum alloys still face challenges. The excellent printable ability, favorable mechanical performance, and low manufacturing cost are the main factors affecting the applicability of the LPBF process for aluminum alloys. This paper reviews the research status of traditional aluminum alloy processing and LPBF aluminum alloy and makes a comparison from various aspects such as microstructures, mechanical properties, application scenarios, and manufacturing costs. At present, the LPBF manufacturing cost for aluminum alloys is 2–120 times higher than that of traditional manufacturing methods, with the discrepancy depending on the complexity of the part. Therefore, it is necessary to promote the further development and application of aluminum alloy 3D printing technology from three aspects: the development of aluminum matrix composite materials reinforced with nanoceramic particles, the development of micro-alloyed aluminum alloy powders specially designed for LPBF, and the development of new technologies and equipment to reduce the manufacturing cost of LPBF aluminum alloy. 

A Review on Traditional Processes and Laser Powder Bed Fusion of Aluminum Alloy Microstructures, Mechanical Properties, Costs, and Applications

From the viewpoint of the poor formability and mechanical anisotropy of laser powder bed fusion (LPBF)-processed NiTi alloys, three different energy densities, i.e., minimum value, median value, and maximum value, were adopted in this work. The anisotropic behavior in the microstructural distribution and tensile properties were explored to evaluate the performance stability of NiTi components within a wide processing window. The results showed that an excellent deposition quality was acquired when the energy density was within the range of 45–75 J/mm3. The phase constitution and microstructural features were similar even under different processing parameters. In a single melting pool, the columnar grains within the body zone exhibited {110}<001> and {100}<011> textures. However, no preferred orientation was observed for the fine dot-like sub-structures within the overlapping zone. The anisotropy in tensile strength and plasticity was mainly attributed to the columnar grains with preferred crystallographic orientation in the body zone. Only a dimple-like morphology was observed on the fracture surface, indicating a ductile tensile failure mechanism. The findings demonstrated that the stable microstructural features and tensile performance of LPBF-processed NiTi components were ensured within a wide processing window (45–75 J/mm3), despite the anisotropic behavior along the transverse and longitudinal tensile directions. 

Anisotropy in microstructural features and tensile performance of laser powder bed fusion NiTi alloys

Densification, Microstructural, and Mechanical Properties of Al-Mn-Mg-Er-Zr Alloy Fabricated by Laser Powder Bed Fusion

In this work, the selective laser melting (SLM) of Sc and Zr modified Al-Mn alloy was systematically investigated, with a particular emphasis on the density behavior, microstructure and mechanical properties. The process parameters were significantly impact on the relative density and the maximum relative density of SLM-processed Al-Mn-Sc-Zr specimens reached 99.8% at the optimized process parameters. With the reduction of energy density, the melting mode of melting pool changed from keyhole mode to conduction mode. At the high energy density, near-spherical pores were generated because of the evaporation of low melting alloy constituents. With the decreasing of energy density, irregular pores were generated, which was mainly caused by the insufficient energy input. The SLM processed Al--Mn-Sc-Zr showed a duplex grain microstructure consisting of regions of columnar grains and equiaxed grains. Good mechanical properties were reached in as-fabricated condition: tensile strength ≥ 426 MPa and elongation to fracture ≥ 18%. Besides, no significant anisotropy was found in the stress–strain behavior between horizontal and vertical building direction.

Densification, microstructure and properties of Sc and Zr modified Al-Mn alloy prepared by selective laser melting

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Densification, microstructure and properties of Sc and Zr modified Al-Mn alloy prepared by selective laser melting