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

The invention provides a screening device and method for mixed steel powder and dissimilar powder for SLM forming, which belongs to the technical field of SLM forming auxiliary equipment. The screening device comprises a feeding barrel, a screening module, a control module, a powder separation module, a recycling barrel and an atmosphere module; the upper portion of the screening module is connected with the feeding barrel through a first pipeline, and the lower portion of the screening module is connected with the upper portion of the powder separation module through a second pipeline; the atmosphere module is connected with the screening module through a third pipeline; the lower part of the powder separation module is connected with the recycling barrel through a fourth pipeline. Beforescreening operation, the control module controls the atmosphere module to inflate and replace the screening module, and the control module controls the screening module and the powder separation module to start screening operation. The screening device is simple in structure and high in separation efficiency. Automatic and safe separation of two kinds of mixed powder containing steel powder and dissimilar powder is achieved. The practicability is high, and the popularization value and significance are achieved.

Screening device and method for mixed steel powder and dissimilar powder for SLM forming

The invention provides a device for enhancing discharge effect of magnesium alloy laser selective melting steam smoke dust, and relates to the technical field of metal powder bed additive manufacturing. The device comprises an industrial personal computer, a controller, a first fan, a second fan, a first electromagnetic valve, a second electromagnetic valve, a third electromagnetic valve, a fourthelectromagnetic valve, a first filtering system, a second filtering system, a first flow guiding plate, a second flow guiding plate, a protective atmosphere system, a laser scanning forming cavity, apressure sensor and an exhaust electromagnetic valve, the industrial personal computer communicates with the controller, the controller communicates with the first electromagnetic valve, the second electromagnetic valve, the third electromagnetic valve, the fourth electromagnetic valve, the first flow guiding plate, the second flow guiding plate, the first fan and the second fan, the two flow guiding plates are symmetrically arranged on the two sides of the laser scanning forming cavity correspondingly, the protective atmosphere system communicates with the laser scanning forming cavity, thepressure sensor is arranged on one side of the laser scanning forming cavity, and the exhaust electromagnetic valve communicates with the pressure sensor. According to the device, when equipment excites a laser beam for processing, the effect of the magnesium alloy steam smoke discharge is strengthened, and the forming process stability and the forming part quality are favorably guaranteed.

Device for enhancing discharge effect of magnesium alloy laser selective melting steam smoke dust

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Papers

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

Screening device and method for mixed steel powder and dissimilar powder for SLM forming

Device for enhancing discharge effect of magnesium alloy laser selective melting steam smoke dust