Direct Laser Metal Deposition of Al 7050 Alloy

Singh, Amrinder; Ramakrishnan, A.; Dinda, G.P.

doi:10.4271/2017-01-0286

Cited by 15 publications

(6 citation statements)

References 13 publications

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“…LMD can be considered an alternative to SLM due to larger deposition rates which is relevant to large parts. Al 7050 has been recently processed using LMD with more than 99% relative density [ 38 ]. Processing AlSi12 using LMD resulted in ~100% dense parts with a tensile strength of 225 MPa and 9 × 10 −2 fracture strain [ 39 ].…”

Section: Introductionmentioning

confidence: 99%

Comparison of Microstructure and Mechanical Properties of Scalmalloy® Produced by Selective Laser Melting and Laser Metal Deposition

et al. 2017

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The second-generation aluminum-magnesium-scandium (Al-Mg-Sc) alloy, which is often referred to as Scalmalloy®, has been developed as a high-strength aluminum alloy for selective laser melting (SLM). The high-cooling rates of melt pools during SLM establishes the thermodynamic conditions for a fine-grained crack-free aluminum structure saturated with fine precipitates of the ceramic phase Al3-Sc. The precipitation allows tensile and fatigue strength of Scalmalloy® to exceed those of AlSi10Mg by ~70%. Knowledge about properties of other additive manufacturing processes with slower cooling rates is currently not available. In this study, two batches of Scalmalloy® processed by SLM and laser metal deposition (LMD) are compared regarding microstructure-induced properties. Microstructural strengthening mechanisms behind enhanced strength and ductility are investigated by scanning electron microscopy (SEM). Fatigue damage mechanisms in low-cycle (LCF) to high-cycle fatigue (HCF) are a subject of study in a combined strategy of experimental and statistical modeling for calculation of Woehler curves in the respective regimes. Modeling efforts are supported by non-destructive defect characterization in an X-ray computed tomography (µ-CT) platform. The investigations show that Scalmalloy® specimens produced by LMD are prone to extensive porosity, contrary to SLM specimens, which is translated to ~30% lower fatigue strength.

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Section: Introductionmentioning

confidence: 99%

Comparison of Microstructure and Mechanical Properties of Scalmalloy® Produced by Selective Laser Melting and Laser Metal Deposition

et al. 2017

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“…DED of high-strength aluminum alloys faces technical challenges due to the high surface reflectivity of Aluminum, and higher laser power input is required to melt the blown aluminum powder completely [60]. This in turn leads to gas porosity by selective evaporation of lighter constituent elements such as Magnesium and Zinc [58,61]. The high coefficient of thermal expansion (CTE) of aluminum alloys leads to shrinkage upon solidification followed by cracking or severe deformation due to intense repetitive thermal cycling during the DED process [62].…”

Section: Directed Energy Deposition Of Aluminum Alloysmentioning

confidence: 99%

“…Moreover, the hardness only increased from (85 AE 4) HV0.5 to (93 AE 2) HV0.5 upon artificial aging. In another study on DED of Al-7050 alloy, hardness of a 100HV was achieved in an as-built, defect-free bulk deposit; subsequent heat treatment increased the hardness to 128 HV [61]. Due to the relative ease of deposition and wide processing window Al-Si alloys have results comparable with those of cast counterparts; however, as of now, high-strength aluminum alloys could not be deposited successfully with DED.…”

Section: Directed Energy Deposition Of Aluminum Alloysmentioning

confidence: 99%

Additively Manufactured High-Strength Aluminum Alloys: A Review

Zafar¹,

Reis²,

Vieira³

et al. 2024

Recent Advancements in Aluminum Alloys

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This chapter summarizes the recent advances in additive manufacturing of high-strength aluminum alloys, the challenges of printability, and defects in their builds. It further intends to provide an overview of the state of the art by outlining potential strategies for the fabrication of bulk products using these alloys without cracking. These strategies include identifying a suitable processing window of additive manufacturing using metallic powders of conventional high-strength aluminum alloys, pre-alloying the powders, and developing advanced aluminum-based composites with reinforcements introduced either by in situ or ex situ methods. The resulting microstructures and the relationship between these alloys’ microstructure and mechanical properties have been discussed. Since post-processing is inevitable in several critical applications, the chapter concludes with a brief account of post-manufacturing heat treatment processes of additively manufactured aluminum alloys.

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“…For DED manufactured specimens of an EN AW-7xxx alloy with high zinc content of 11.9% and high magnesium content of 2.7% the measured Vickers hardness increased after a T6 heat treatment from (133 ± 6) HV0.05 to (219 ± 4) HV0.05 [13]. When processing EN AW-7xxx alloys in DED processes a loss in volatile elements such as zinc and magnesium is observed [14]. This alters the initial alloy composition and can affect the (mechanical) properties.…”

Section: Introductionmentioning

confidence: 98%

Mechanical Properties of High Strength Aluminum Alloy EN AW-7075 Additively Manufactured by Directed Energy Deposition

Langebeck

Bohlen

Rentsch

et al. 2020

Metals

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A manifold variety of additive manufacturing techniques has a significant positive impact on many industry sectors. Large components are often manufactured via directed energy deposition (DED) instead of using powder bed fusion processes (PBF). The advantages of the DED process are a high build-up rate with values up to 300 cm3/h and a nearly limitless build-up volume. In combination with the lightweight material aluminum it is possible to manufacture large lightweight components with geometries adapted to customer requirements in small batches. This contributes the pursuit of higher efficiency of machines through lightweight materials as well as lightweight design. A low-defect additive manufacturing of high strength aluminum EN AW-7075 powder via DED is an important challenge. The laser power has a significant influence on the remaining porosity. By increasing the laser power from 2 kW to 4 kW the porosity in single welding tracks can be lowered from 2.1% to only (0.09 ± 0.07)% (n = 3). However, when manufacturing larger specimens; the remaining porosity is higher than in single tracks; which can be attributed to the oxide skin on the preceding welding tracks. Further investigations regarding the mechanical properties were carried out. In tensile tests an ultimate tensile strength of (222 ± 17) MPa (n = 6) was measured. The DED processed EN AW-7075 shows comparable mechanical properties to PBF processed EN AW-7075.

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Direct Laser Metal Deposition of Al 7050 Alloy

Cited by 15 publications

References 13 publications

Comparison of Microstructure and Mechanical Properties of Scalmalloy® Produced by Selective Laser Melting and Laser Metal Deposition

Comparison of Microstructure and Mechanical Properties of Scalmalloy® Produced by Selective Laser Melting and Laser Metal Deposition

Additively Manufactured High-Strength Aluminum Alloys: A Review

Mechanical Properties of High Strength Aluminum Alloy EN AW-7075 Additively Manufactured by Directed Energy Deposition

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