Exploiting the rapid solidification potential of laser powder bed fusion in high strength and crack-free Al-Cu-Mg-Mn-Zr alloys

被引:90
作者
Li, Guichuan [1 ]
Brodu, Etienne [1 ]
Soete, Jeroen [1 ]
Wei, Huiliang [2 ]
Liu, Tingting [2 ]
Yang, Tao [2 ]
Liao, Wenhe [2 ]
Vanmeensel, Kim [1 ]
机构
[1] Katholieke Univ Leuven, Dept Mat Engn, Kasteelpk Arenberg 44, B-3001 Heverlee, Belgium
[2] Nanjing Univ Sci & Technol, Sch Mech Engn, Nanjing 210094, Peoples R China
关键词
Additive manufacturing; Aluminum alloy; Hot crack; Microstructure; Grain refinement; Strengthening mechanism; MECHANICAL-PROPERTIES; GRAIN-REFINEMENT; ALUMINUM-ALLOY; HOT CRACKING; MICROSTRUCTURE; SC; TI; PRECIPITATION; INOCULATION; FORMABILITY;
D O I
10.1016/j.addma.2021.102210
中图分类号
T [工业技术];
学科分类号
08 ;
摘要
This work describes a systematic alloy design strategy resulting in the development of a high strength aluminum alloy adopted for L-PBF. First, based on the composition of a reference Al-Cu-Mg alloy, three Al-Cu-Mg-Mn-Zr-based alloys were investigated using computational thermodynamic tools. Subsequently, the L-PBF processing behavior, microstructure, and concomitant mechanical properties of the L-PBF-fabricated alloys were investigated. Alloys with different compositions showed substantial differences in microstructure: the alloy without Zr addition showed a coarse columnar microstructure and suffered from solidification cracking, alloys with low to mediate Zr additions (1-1.98 wt%) showed a mixed columnar and equiaxed microstructure, while alloys with high Zr addition (3.72 wt%) showed a fully equiaxed microstructure, accompanied by a grain size reduction down to 0.7 +/- 0.3 mu m. All alloys containing >= 1.98 wt% Zr were crack-free. The L-PBF-processed Al-4.40Cu1.51Mg-1.15Mn-3.72Zr (wt%) alloy showed an extended Zr solid solubility in the Al matrix of similar to 1.3 +/- 0.1 wt %. Coherent primary Al3Zr particles with a cubic L12 structure were formed in all the Zr-containing alloys. The mechanical properties of as-built alloys increased consistently with increasing Zr contents from 0 to 3.72 wt%. The designed Al-4.40Cu-1.51Mg-1.15Mn-3.72Zr (wt%) alloy combined a yield strength of 561 +/- 24 MPa, an ultimate tensile strength of 580 +/- 16 MPa, and an elongation at break of 6.0 +/- 1.3%. The exceptionally high strength of this alloy is attributed to a combination of grain refinement, Orowan, solid solution, and dislocation strengthening. The current work shows the intrinsic potential of rapid solidification occurring during L-PBF for the fabrication of geometrically-complex, high-strength lightweight parts made of ultra-fine-grained hyperperitectic aluminum alloys containing transition element additions.
引用
收藏
页数:17
相关论文
共 80 条
[1]   Evaluation of solidification cracking susceptibility during laser welding in advanced high strength automotive steels [J].
Agarwal, G. ;
Kumar, A. ;
Richardson, I. M. ;
Hermans, M. J. M. .
MATERIALS & DESIGN, 2019, 183
[2]   Additively manufactured novel Al-Cu-Sc-Zr alloy: Microstructure and mechanical properties [J].
Agrawal, Priyanka ;
Gupta, Sanya ;
Thapliyal, Saket ;
Shukla, Shivakant ;
Haridas, Ravi Sankar ;
Mishra, Rajiv S. .
ADDITIVE MANUFACTURING, 2021, 37
[3]   Scanning strategies for texture and anisotropy tailoring during selective laser melting of TiC/316L stainless steel nanocomposites [J].
AlMangour, Bandar ;
Grzesiak, Dariusz ;
Yang, Jenn-Ming .
JOURNAL OF ALLOYS AND COMPOUNDS, 2017, 728 :424-435
[4]  
Anderson K., PROP SEL ALUM ALLOY, V298, P303, DOI [10.31399/asm.hb.v02b.a0006598, DOI 10.31399/ASM.HB.V02B.A0006598]
[5]  
[Anonymous], 1990, METALS HDB
[6]   New Aluminum Alloys Specifically Designed for Laser Powder Bed Fusion: A Review [J].
Aversa, Alberta ;
Marchese, Giulio ;
Saboori, Abdollah ;
Bassini, Emilio ;
Manfredi, Diego ;
Biamino, Sara ;
Ugues, Daniele ;
Fino, Paolo ;
Lombardi, Mariangela .
MATERIALS, 2019, 12 (07)
[7]   Interface velocity dependent solute trapping and phase selection during rapid solidification of laser melted hypo-eutectic Al-11at.%Cu alloy [J].
Bathula, Vishwanadh ;
Liu, Can ;
Zweiacker, Kai ;
McKeown, Joseph ;
Wiezorek, Jorg M. K. .
ACTA MATERIALIA, 2020, 195 :341-357
[8]   Study of Luders phenomena in reactor pressure vessel steels [J].
Beardsmore, D. W. ;
da Fonseca, J. Quinta ;
Romero, J. ;
English, C. A. ;
Ortner, S. R. ;
Sharples, J. ;
Sherry, A. H. ;
Wilkes, M. A. .
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING, 2013, 588 :151-166
[9]   Promoting the columnar to equiaxed transition and grain refinement of titanium alloys during additive manufacturing [J].
Bermingham, M. J. ;
StJohn, D. H. ;
Krynen, J. ;
Tedman-Jones, S. ;
Dargusch, M. S. .
ACTA MATERIALIA, 2019, 168 :261-274
[10]   Electronic Cigarette Use Among Patients With Cancer [J].
Borderud, Sarah P. ;
Li, Yuelin ;
Burkhalter, Jack E. ;
Sheffer, Christine E. ;
Ostroff, Jamie S. .
CANCER, 2014, 120 (22) :3527-3535