Additive manufacturing of crack-free Al-alloy with coarsening-resistant t1-CeAlSi strengthening phase

Wrought aluminium alloys popular for automotive and aerospace applications are susceptible to solidification cracking when fabricated via laser powder bed fusion (LPBF). Another long-standing and common issue for these alloys is microstructure coarsening and corresponding strength loss caused by elevated temperature exposure. To tackle these challenges, this study designs and develops a class of 1-4 wt% Ce modified Al6061 alloys. The best alloy, with 3 wt% Ce, achieves crack-free fabrication via LPBF due to a reduction in the solidification temperature range and a new solidification pathway that achieved 0.9 solid mass fraction at just 14 degrees C below the solidification onset. Furthermore, a fine microstructure consisting of coarsening-resistant & tau;1-CeAlSi eutectic forms, and after hot isostatic pressing, the tensile strength and elongation of the 3 wt% Ce alloy can reach 153 & PLUSMN; 6 MPa and 18.3% at room temperature and 89 & PLUSMN; 6 MPa and 32.5% at 200 degrees C, respectively. The observed ductility is attributed to nanoscale dispersion of discrete, coarsening resistant & tau;1-CeAlSi particles within grains and to the presence of large columnar & alpha;-Al grains. Meanwhile, solidification cracking was inhibited by continuous grain boundary & tau;1-CeAlSi eutectic accumulation, which converted to discrete nanoscale & tau;1-CeAlSi after hot isostatic pressing. This research uncovers a simple and effective approach of designing Al-alloys for LPBF with great potential for both room temperature and high temperature applications in automotive and aerospace industries.