On the microstructure and solidification behavior of new generation additively manufactured Al-Cu-Mg-Ag-Ti-B alloys

Ghoncheh, M.H.; Sanjari, Mehdi; Zoeram, A. Shojaei; Cyr, Edward; Amirkhiz, Babak Shalchi; Lloyd, Alan; Haghshenas, M.; Mohammadi, Mohsen

doi:10.1016/j.addma.2020.101724

Cited by 26 publications

(9 citation statements)

References 49 publications

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“…If standard alloys are used, such as Aluminium 6061/7075, this can lead to two issues in PBF-LB: severe solidification cracking and evaporation of low melting elements such as Zn or Mg [7,8]. Some researchers have addressed the solidification cracking issue by modifying the solidification process of aluminium by creating alternate solidification paths for Al-grains by providing nucleants (such as Al 3 (Sc,Zr) or TiB 2 ) Article [7,9], whereby the formation of columnar Al-grains is avoided by breaking them up into smaller equiaxed grains. Another way could be to develop grades of aluminium alloys that are less prone to solidification cracking owing to inherent lower solidification cracking susceptibility [10,11].…”

Section: Introductionmentioning

confidence: 99%

Al–Mn–Cr–Zr-based alloys tailored for powder bed fusion-laser beam process: Alloy design, printability, resulting microstructure and alloy properties

Mehta

Nyborg

Frisk

et al. 2022

Journal of Materials Research

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This study introduces a family of unique Al–Mn–Cr–Zr-based aluminium alloys illustrated by two ternary and one quaternary variants. The choice of alloy compositions has created a system resistant to solidification cracking while retaining high amount of solutes in solid solution in as-printed condition. Good relative density (~ 99.5%) has been demonstrated along with microstructural study supported by X-ray diffraction to display solidification structure with nanometric precipitate formation in small amounts in as-printed condition. High levels of Mn and Cr produce significant solid solution strengthening reaching hardness of up to 102 HV in as-printed condition. Additionally, the combination of Mn, Cr and Zr is shown to be important to control precipitation strengthening upon direct ageing and coarsening resistance due to slow diffusivity. To elucidate the concept of precipitation strengthening, one set of alloys was aged at 678 K between 0 and 10 h and microhardness results showed that average hardness response reached 130 HV for the quarternary alloy. Graphical abstract

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Section: Introductionmentioning

confidence: 99%

Al–Mn–Cr–Zr-based alloys tailored for powder bed fusion-laser beam process: Alloy design, printability, resulting microstructure and alloy properties

Mehta

Nyborg

Frisk

et al. 2022

Journal of Materials Research

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“…Compared to the LPBF printed Ti-modified Al-Cu-Mg alloys, the grain size in the present work is significantly smaller (0.86 μm vs. 1.64 μm), while the maximum texture intensity is similar (1.1 vs. 1.188)[55]. Compared to LPBFed Ti-modified A205 alloys, the grain size in the present work is similar (0.86 μm vs. 0.96 μm), while the maximum texture intensity is smaller (1.1 vs. 1.36)[37]. The calculated texture J-index[56] is 1.02 which confirms the material exhibits a weak texture (where unity J-index corresponds to a random texture while a single crystal texture has infinity J-index).…”

mentioning

confidence: 37%

“…The standard tensile tests show similar mechanical properties to the in situ tests despite the different sample morphology. Figure 8b and Ti-modified Al-Cu alloys [37,55], but higher than the TiB 2 pre-doped A205 alloys (269 MPa) [37].…”

Section: Mechanical Propertiesmentioning

confidence: 83%

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Synchrotron Characterisation of Ultra-Fine Grain TiB2/Al-Cu Composite Fabricated by Laser Powder Bed Fusion

Cai

Duan

et al. 2021

Acta Metall. Sin. (Engl. Lett.)

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Isotropy in microstructure and mechanical properties remains a challenge for laser powder bed fusion (LPBF) processed materials due to the epitaxial growth and rapid cooling in LPBF. In this study, a high-strength TiB2/Al-Cu composite with random texture was successfully fabricated by laser powder bed fusion (LPBF) using pre-doped TiB2/Al-Cu composite powder. A series of advanced characterisation techniques, including synchrotron X-ray tomography, correlative focussed ion beam–scanning electron microscopy (FIB-SEM), scanning transmission electron microscopy (STEM), and synchrotron in situ X-ray diffraction, were applied to investigate the defects and microstructure of the as-fabricated TiB2/Al-Cu composite across multiple length scales. The study showed ultra-fine grains with an average grain size of about 0.86 μm, and a random texture was formed in the as-fabricated condition due to rapid solidification and the TiB2 particles promoting heterogeneous nucleation. The yield strength and total elongation of the as-fabricated composite were 317 MPa and 10%, respectively. The contributions of fine grains, solid solutions, dislocations, particles, and Guinier–Preston (GP) zones were calculated. Failure was found to be initiated from the largest lack-of-fusion pore, as revealed by in situ synchrotron tomography during tensile loading. In situ synchrotron diffraction was used to characterise the lattice strain evolution during tensile loading, providing important data for the development of crystal-plasticity models.

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“…At TiB 2 fractions >∼1 wt-%, a refined and equiaxed submicron grain structure is produced in Al-Si-(Mg) alloys during LPBF [142][143][144][145], Figure 11(a,b), as well as DED processing of an Al7075 alloy [146]. In addition to mechanical mixing of TiB 2 and Al powders, TiB 2 may be incorporated into an alloy ingot through in-situ metal salt reaction, with the entire ingot then atomised for AM processing [147][148][149][150]. In these cases, Ti that dissolves into the matrix during the complex processing also contributes to constitutional supercooling, increasing the nucleation rate of equiaxed grains.…”

Section: Grain Structurementioning

confidence: 99%

Towards high-temperature applications of aluminium alloys enabled by additive manufacturing

Michi

Plotkowski

Shyam

et al. 2021

International Materials Reviews

147

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Research on powder-based additive manufacturing of aluminium alloys is rapidly increasing, and recent breakthroughs in printing of defect-free parts promise substantial movement beyond traditional Al-Si-Mg) systems. One potential technological advantage of aluminium additive manufacturing, however, has received little attention: the design of alloys for use at T >~200°C, or~1/2 of the absolute melting temperature of aluminium. Besides offering lightweighting and improved energy efficiency through replacement of ferrous, titanium, and nickel-based alloys at 200-450°C, development of such alloys will reduce economic roadblocks for widespread implementation of aluminium additive manufacturing. We herein review the existing additive manufacturing literature for three categories of potential hightemperature alloys, discuss strategies for optimizing microstructures for elevatedtemperature performance, and highlight gaps in current research. Although extensive microstructural characterisation has been performed on these alloys, we conclude that evaluations of their high-temperature mechanical properties and corrosion responses are severely deficient.

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On the microstructure and solidification behavior of new generation additively manufactured Al-Cu-Mg-Ag-Ti-B alloys

Cited by 26 publications

References 49 publications

Al–Mn–Cr–Zr-based alloys tailored for powder bed fusion-laser beam process: Alloy design, printability, resulting microstructure and alloy properties

Al–Mn–Cr–Zr-based alloys tailored for powder bed fusion-laser beam process: Alloy design, printability, resulting microstructure and alloy properties

Synchrotron Characterisation of Ultra-Fine Grain TiB2/Al-Cu Composite Fabricated by Laser Powder Bed Fusion

Towards high-temperature applications of aluminium alloys enabled by additive manufacturing

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