Alloying AlSi10Mg and Cu powders in laser Single Scan Tracks, melt spinning, and Laser Powder Bed Fusion

Marola, Silvia; Gianoglio, Dario; Bosio, Federico; Aversa, Alberta; Lorusso, Massimo; Manfredi, Diego; Lombardi, Mariangela; Battezzati, Livio

doi:10.1016/j.jallcom.2019.153538

Cited by 17 publications

(5 citation statements)

References 25 publications

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“…Before the heat treatments, asbuilt samples show a hardness value of 100.5 ± 3 HV that is significantly far lower than those reported in the literature. 23,24 Hence, it seems that AlSi10Mg samples are already overaged after 10 h of printing time at 200°C. After isothermal heat treatment at 200°C for 100 h, a further decrease in hardness down to 91 ± 0.62 HV was revealed.…”

Section: Resultsmentioning

confidence: 99%

Production Strategy for Manufacturing Large-Scale AlSi10Mg Components by Laser Powder Bed Fusion

Bosio

Shen

Liu

et al. 2021

JOM

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The long production time required for large-scale parts fabricated by laser powder bed fusion (LPBF) tends to induce cracks, distortions, and overheating problems. In this work, to address these challenges, we explored and established a suitable strategy for producing large AlSi10Mg components. The platform temperatures to prevent cracks and distortions were firstly determined. Then, the in situ aging behavior was investigated for samples under various platform temperatures and holding times. Our results revealed that platform temperatures of 150°C and 200°C can effectively prevent cracks and minimize distortions. Besides, using 150°C, samples can reach peak hardness with a holding time less than 13 h. In comparison, those samples produced with a holding time longer than 13 h at 150°C and 200°C show obvious overaging responses and thus lower hardness. However, such a hardness impoverishment can be recovered by using a T6 post-process heat-treatment.

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Section: Resultsmentioning

confidence: 99%

Production Strategy for Manufacturing Large-Scale AlSi10Mg Components by Laser Powder Bed Fusion

Bosio

Shen

Liu

et al. 2021

JOM

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Section: Discussionmentioning

confidence: 99%

“…A large body of literature demonstrated the benefits of adding 4 wt% Cu to the well-known AlSI10Mg system [22][23][24][25][26]. However, most of the studies on the processability of this composition were carried out on the system obtained from mechanically mixed powders of AlSi10Mg and pure Cu [22][23][24]26]. Despite being effortless and cost-saving, this method of obtaining feedstock material based on AlSi10Mg and pure Cu powders leads to significant inhomogeneities of the alloying elements and thus to non-uniform mechanical properties [26].…”

Section: Discussionmentioning

confidence: 99%

“…One methodology recently explored to obtain Al-Si-Cu-Mg systems for PBF-LB/M technologies is through the addition of Cu to the well-known AlSi10Mg alloy. To the best of the authors' knowledge, these systems have been obtained in three different routes: powder coating [21], powder mixing [22][23][24] and using pre-alloyed powders [25]. As reported by Garmendia et al, coating AlSi10Mg powders with 1 wt% Cu led to promising results in terms of hardness and tensile strengths.…”

Section: Introductionmentioning

confidence: 99%

“…The mechanical mix of 4 wt% Cu and AlSi10Mg powders was studied in literature resulting in an increase of about 9% in microhardness and about 35% in YS, compared to the pure AlSi10Mg alloy [23]. Despite the promising results obtained with the mechanical mixing method, undesirable clusters of unevenly dissolved Cu were detected [22][23][24]26]. The most effective way to obtain these systems without stringent Cu limits and homogenisation problems could be through the use of pre-alloyed powder.…”

Section: Introductionmentioning

confidence: 99%

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Improvement in the PBF-LB/M processing of the Al-Si-Cu-Mg composition through the use of pre-alloyed powder

Martucci

Gobber

Aversa

et al. 2023

Mater. Res. Express

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Among the many additive manufacturing technologies for metals, Powder Bed Fusion-Laser Beam (PBF-LB\M) stands out for its capacity to produce complex-shaped functional parts. However, the PBF-LB\M materials portfolio is still limited and the research into new high-performance Al-based alloys is ongoing. The improved properties with the addition of 4 wt% Cu to the AlSi10Mg alloy have been previously investigated in the literature through the in-situ alloying approach in which the starting powders of Cu and AlSi10Mg are mechanically mixed and directly processed. However, inhomogeneities of alloying elements were found in samples produced with mixed AlSi10Mg+4Cu powders. To overcome this issue, the use of pre-alloyed AlSI10Cu4Mg powder obtained via gas atomisation process could be a powerful solution. With the aim of demonstrating the beneficial effects of pre-alloyed AlSi10Cu4Mg powders in laser-powder interaction, preliminary SEM investigations were conducted on cross-sectioned SSTs and bulk samples after optimising the process parameters. The microstructural investigations conducted on pre-alloyed AlSi10Cu4Mg samples revealed a higher homogeneity of alloying elements, a smaller cell size of the Al-Si-Cu network (0.5 vs 0.8 µm) and a slightly smaller mean diameter of equiaxial grains compared to the mixed AlSi10Mg+4Cu ones (6.01 vs 7.34 µm). Moreover, looking closer at the supersaturation level and the precipitation behaviour in pre-alloyed AlSi10Cu4Mg composition, a high solid solution level, a massive presence of Al2Cu in the cell network and only a few finely dispersed Al2Cu precipitates within the cells were found. Exploring the benefits of these microstructural features on mechanical properties, an increase in performance of about 18 % in micro-hardness tests and more than 10 % in tensile and compressive tests were found in the AlSi10Cu4Mg system with respect to the mixed AlSi10Mg+4Cu system. All the thorough investigations proved how using pre-alloyed powders is an important advantage in the PBF-LB/M production of complex Al-based systems.

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Effect of Thermal Exposure Simulating Vapor Deposition on the Impact Behavior of Additively Manufactured AlSi10Mg Alloy

Lattanzi

Merlin

Fortini

et al. 2021

J. of Materi Eng and Perform

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The present work focuses on the evolution of hardness and impact toughness after thermal exposure at high temperatures of the AlSi10Mg alloy produced by selective laser melting. The thermal exposure simulated the vapor deposition of coatings on aluminum alloys. The aim is to assess the possibility of combining the ageing step of heat treatments and the deposition treatment. The alloy was aged at 160 and 180 °C for up to 4 hours, both directly and after an innovative rapid solution treatment. Direct ageing had no significant effects on the microstructure, showing an almost constant hardness trend. These results accord with the impact properties, which showed a negligible difference in the impact toughness of the direct aged and the as-built samples. The same ageing treatments performed after rapid solution treatment induced age hardening in the alloy. The hardness values were lower by 38% than those of the directly aged samples. The innovative solution treatment positively affected impact toughness, which increased by 185% compared to the directly aged material. These results highlight that the ageing step can be integrated with the vapor deposition process. Moreover, the heat treatment is suitable for components requiring high impact strength after coating.

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Alloying AlSi10Mg and Cu powders in laser Single Scan Tracks, melt spinning, and Laser Powder Bed Fusion

Cited by 17 publications

References 25 publications

Production Strategy for Manufacturing Large-Scale AlSi10Mg Components by Laser Powder Bed Fusion

Production Strategy for Manufacturing Large-Scale AlSi10Mg Components by Laser Powder Bed Fusion

Improvement in the PBF-LB/M processing of the Al-Si-Cu-Mg composition through the use of pre-alloyed powder

Effect of Thermal Exposure Simulating Vapor Deposition on the Impact Behavior of Additively Manufactured AlSi10Mg Alloy

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