A new Al-Cu alloy for LPBF developed via ultrasonic atomization

Monti, Chiara; Turani, Matteo; Papis, Konrad J. M.; Bambach, Markus

doi:10.1016/j.matdes.2023.111907

Cited by 14 publications

(3 citation statements)

References 33 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Parts of the grain refiners can react with the matrix in situ to form L1 2 -Al 3 X(X for Sc, Zr, Ti) precipitations [19][20][21]. These Al 3 X precipitations are super-effective nucleating agents for grain refinement during the printing process due to a low lattice misfit with aluminum.…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Mechanical Properties of a Novel Al-Mg-Sc-Ti Alloy Fabricated by Laser Powder Bed Fusion

Shu,

Liu

2024

Materials

View full text Add to dashboard Cite

(TiH2 + ScH3)/Al-Mg composite powders with different Ti contents were produced by ball milling. These composite powders were fabricated to cube and cuboid shape samples via a laser powder bed fusion process with optimal processing parameters. The TiH2 and ScH3 particles underwent dehydrogenation during the laser powder bed fusion process, and these composite powders ultimately formed Al-Mg-Sc-Ti alloys. The relative density, printability, microstructure, hardness and tensile properties of these alloy samples were investigated. The results show that these Al-Mg-Sc-Ti alloys have lower hot-crack sensitivity, having fine equiaxed grains. An Al18Mg3(Ti,Sc)2 intermetallic phase and in situ L12-Al3(Sc,Ti) precipitations formed during the laser powder bed fusion process, which is beneficial for nucleation and dispersion strengthening. The ultimate tensile strength of the Al-Mg-0.7Sc-1.0Ti alloy was 313.6 MPa with an elongation of 6.6%. During the hot isostatic pressing treatment, most of the Mg element precipitated from the matrix and changed the Al3(Sc,Ti) into a Al18Mg3(Ti,Sc)2 precipitate completely. The Al-Mg-Sc-Ti alloys were nearly fully dense after the hot isostatic pressing treatment and exhibited better mechanical properties. The ultimate tensile strength of the Al-Mg-0.7Sc-1.0Ti was 475 MPa with an elongation of 8.5%.

show abstract

Section: Introductionmentioning

confidence: 99%

Microstructure and Mechanical Properties of a Novel Al-Mg-Sc-Ti Alloy Fabricated by Laser Powder Bed Fusion

Shu,

Liu

2024

Materials

View full text Add to dashboard Cite

show abstract

“…These developments are making AM methods a viable solution for a wide range of realworld production applications. The increasing variety of new powder materials, designed with an optimized particle size, distribution, and chemical properties for powder-bed fusion processes, is providing numerous AM enthusiasts with the opportunity to apply the process to their industry applications [4][5][6]. Major players in the metal AM industry, such as EOS GmbH, GE, Nikon/SLM Solutions, Aconity GmbH, IAMG and Renishaw, are offering parameter sets for fabricating parts from commonly used metal materials (such as Ti grade 1-5, Co-Cr/Co-Cr-Mo, AlSi10Mg, various steels, nickel alloys, and copper alloys) with densities close to the theoretical values.…”

Section: Introductionmentioning

confidence: 99%

Mechanical Properties of Ti Grade 2 Manufactured Using Laser Beam Powder Bed Fusion (PBF-LB) with Checkerboard Laser Scanning and In Situ Oxygen Strengthening

Wysocki,

Chmielewska-Wysocka,

Maj

et al. 2024

Crystals

View full text Add to dashboard Cite

Additive manufacturing (AM) technologies have advanced from rapid prototyping to becoming viable manufacturing solutions, offering users both design flexibility and mechanical properties that meet ISO/ASTM standards. Powder bed fusion using a laser beam (PBF-LB), a popular additive manufacturing process (aka 3D printing), is used for the cost-effective production of high-quality products for the medical, aviation, and automotive industries. Despite the growing variety of metallic powder materials available for the PBF-LB process, there is still a need for new materials and procedures to optimize the processing parameters before implementing them into the production stage. In this study, we explored the use of a checkerboard scanning strategy to create samples of various sizes (ranging from 130 mm3 to 8000 mm3 using parameters developed for a small 125 mm3 piece). During the PBF-LB process, all samples were fabricated using Ti grade 2 and were in situ alloyed with a precisely controlled amount of oxygen (0.1–0.4% vol.) to enhance their mechanical properties using a solid solution strengthening mechanism. The samples were fabricated in three sets: I. Different sizes and orientations, II. Different scanning strategies, and III. Rods for high-cycle fatigue (HCF). For the tensile tests, micro samples were cut using WEDM, while for the HCF tests, samples were machined to eliminate the influence of surface roughness on their mechanical performance. The amount of oxygen in the fabricated samples was at least 50% higher than in raw Ti grade 2 powder. The O2-enriched Ti produced in the PBF-LB process exhibited a tensile strength ranging from 399 ± 25 MPa to 752 ± 14 MPa, with outcomes varying based on the size of the object and the laser scanning strategy employed. The fatigue strength of PBF-LB fabricated Ti was 386 MPa, whereas the reference Ti grade 2 rod samples exhibited a fatigue strength of 312 MPa. Our study revealed that PBF-LB parameters optimized for small samples could be adapted to fabricate larger samples using checkerboard (“island”) scanning strategies. However, some additional process parameter changes are needed to reduce porosity.

show abstract

“…The results demonstrated that the addition of Cr promotes the precipitation of an Al-Cu-Y-Cr phase, improving mechanical responses, especially after rolling and annealing processes. Monti et al [21] investigated the effect of Cr and Fe addition on the hot cracking formation in Al-Cu alloys processed by laser powder bed fusion (LPBF). Secondary phase formation and microstructure refining were examined under high cooling rates.…”

Section: Introductionmentioning

confidence: 99%

Microstructure, Hardness, and Linear Reciprocating Sliding Wear Response of Directionally Solidified Al–(2.5, 3.5, 4.5)Cu–(0.25, 0.50)Cr Alloys

Lantmann,

Mariante,

Pinheiro

et al. 2023

Metals

View full text Add to dashboard Cite

Aluminum alloys containing transition metal alloying elements have attracted interest from researchers. The effect of Cr additions of 0.25 and 0.50% on the thermal profile, microstructure, hardness, and linear reciprocating sliding wear response of as-cast hypoeutectic Al–Cu alloys with 2.5, 3.5, and 4.5% Cu (wt.%) was investigated. The binary Al–Cu and ternary Al–Cu–Cr alloys were directionally solidified under upward non-steady state heat transfer conditions using a dedicated solidification apparatus. Thermal analysis based on differential thermal analysis (DTA) and cooling curve profiles was performed to determine solidification thermal parameters such as Liquidus temperature (TL), transformation enthalpy (ΔH), and liquid cooling rate (ṪL). Samples extracted from the solidified ingots were submitted to optical microscopy, hardness measurement, and linear reciprocating sliding wear test using a high-frequency reciprocating rig (HFRR). The results showed a decrease at the beginning of solidification (TL) and of the transformation enthalpy (ΔH) when both alloy Cu and Cr contents increased, with a higher influence of Cu. The addition of Cu decreased cooling rates, whereas the increase in the alloy Cr concentration showed an opposite behavior, increasing cooling rates. The refinement of the primary dendrite arm spacing (λ1), as a consequence of the increase in alloying elements and solidification cooling rates, enhanced the hardness of the alloys, with the maximum value of 58 HB achieved in the ternary Al–4.5Cu–0.50Cr alloy. The wear tests indicated a better response to wear associated with microstructure refinement for the alloys with 2.5% Cu, for both Cr contents, an almost constant behavior for the 3.5% Cu alloys, and an opposite performance for the alloys with 4.5% Cu alloys that showed better wear resistance with coarsening of the λ1 and with the increase in the amount of the eutectic microconstituent.

show abstract

A new Al-Cu alloy for LPBF developed via ultrasonic atomization

Cited by 14 publications

References 33 publications

Microstructure and Mechanical Properties of a Novel Al-Mg-Sc-Ti Alloy Fabricated by Laser Powder Bed Fusion

Microstructure and Mechanical Properties of a Novel Al-Mg-Sc-Ti Alloy Fabricated by Laser Powder Bed Fusion

Mechanical Properties of Ti Grade 2 Manufactured Using Laser Beam Powder Bed Fusion (PBF-LB) with Checkerboard Laser Scanning and In Situ Oxygen Strengthening

Microstructure, Hardness, and Linear Reciprocating Sliding Wear Response of Directionally Solidified Al–(2.5, 3.5, 4.5)Cu–(0.25, 0.50)Cr Alloys

Contact Info

Product

Resources

About