Practical Approach to Eliminate Solidification Cracks by Supplementing AlMg4.5Mn0.7 with AlSi10Mg Powder in Laser Powder Bed Fusion

Böhm, Constantin; Werz, Martin; Weihe, Stefan

doi:10.3390/ma15020572

Cited by 10 publications

(3 citation statements)

References 43 publications

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“…Al-Si-Mg casting alloys were widely used in aerospace, military and automotive fields because of their light weight, excellent casting properties, good fatigue and corrosion resistance, and high specific strength [1][2][3][4][5]. However, due to the coarse size of α-Al grains and slab-like eutectic silicon in Al-Si-Mg casting alloy, which the mechanical properties of the alloy were reduced, and its application range was limited [6,7].…”

Section: Introductionmentioning

confidence: 99%

Study on mechanism of refining and modifying in Al–Si–Mg casting alloys with adding rare earth cerium

Cui

Wang

Chen

et al. 2023

Mater. Res. Express

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In this paper, Al-7%Si-0.6%Mg-X%Ce (X=0, 0.1 and 0.2) casting alloys were prepared by vacuum induction furnace. Using optical microscopy (OM), X-ray diffractometer (XRD), scanning electron microscopy (SEM), energy spectrometry (EDS), differential scanning calorimetry (DSC) and transmission electron microscopy (TEM), the microstructures of the experimental alloys were studied, and the mechanism of refinement and modification of the alloy were discussed. Results show that AlCeSi2 was formed after adding cerium element in the Al alloy, besides those compounds of α-Al, silicon, eutectic of α-Al + Si and iron-rich phase. Furthermore, with the increase of cerium addition, α- Al dendrite arms decrease, the AlCeSi2 was formed, and the growth of iron-rich phase was hindered, respectively. Also, the areas of eutectic of α-Al + Si were decreased, due to the supercooling increasing of the alloys. In addition, the α-Al grains were refined, because existing of heterogeneous nucleation core supplied by AlCeSi2, and component supercooling caused by cerium adding. Moreover, the formation of AlCeSi2 consumed to some silicon elements, which leaded to size and amount reduction of eutectic silicon. The formation of high-density stacking fault can induce silicon modified, and the formed high-density stacking fault was produced by cerium as impurity element into silicon.

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Section: Introductionmentioning

confidence: 99%

Study on mechanism of refining and modifying in Al–Si–Mg casting alloys with adding rare earth cerium

Cui

Wang

Chen

et al. 2023

Mater. Res. Express

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“…Therefore, the hot cracking sensitivity depends on the chemical composition [39], since alloying elements can differently affect the solidification rate. Existing countermeasures to reduce hot cracking are high-temperature preheating [40] or the alloying of the powder for processing in PBF-LB/M [41]. The introduction of beam shaping through the AFX-1000 laser could have positive effects on productivity.…”

Section: Introductionmentioning

confidence: 99%

Influence of Novel Beam Shapes on Laser-Based Processing of High-Strength Aluminium Alloys on the Basis of EN AW-5083 Single Weld Tracks

Nahr¹,

Bartels²,

Rothfelder³

et al. 2023

JMMP

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The commonly used Gaussian intensity distribution during the laser-based processing of metals can negatively affect melt pool stability, which might lead to defects such as porosity, hot cracking, or poor surface quality. Hot cracking is a major factor in limiting production rates of high-strength aluminium alloys in laser-based processes such as welding or the powder bed fusion of metals (PBF-LB/M). Going away from a Gaussian intensity distribution to ring-shaped profiles allows for a more even heat distribution during processing, resulting in more stable melt pools and reduced defect formations. Therefore, the aim of this study is to investigate the influence of different laser beam profiles on the processing of high-strength aluminium alloys by using a multicore fiber laser, allowing for in-house beam shaping. Single weld tracks on the aluminium alloy EN AW-5083 are produced with varying laser powers and weld speeds, as well as different beam profiles, ranging from Gaussian intensity distribution to point/ring profiles. The molten cross sections are analyzed regarding their geometry and defects, and the surface roughness of the weld tracks is measured. By using point/ring beam profiles, the processing window can be significantly increased. Hot cracking is considerably reduced for weld speeds of up to 1000 mm/s compared to the Gaussian beam profile. Furthermore, the melt pool width and depth are more stable, with varying parameters for the point/ring profiles, while the Gaussian beam tends to keyhole formation at higher beam powers. Finally, a strong decrease in surface roughness for the point/ring profiles, accompanied by a significantly reduced humping effect, starting even at lower beam powers of 200 W, can be observed. Therefore, these results show the potential of beam shaping for further applications in laser-based processing of high-strength aluminium alloys.

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“…Chen et al studied the effect of laser scanning speed on the microstructure and mechanical properties of K418 nickel-based alloy produced by laser powder bed fusion [20]. Böhm et al evaluated the feasibility of using a mixture of two aluminium alloys to eliminate solidification cracks formed during laser powder bed fusion [21]. Chen et al studied the fabrication of bimetallic structures using TiNi-based shape memory alloy by laser-directed energy deposition [22].…”

mentioning

confidence: 99%

Emerging Materials for Additive Manufacturing

Sing

Yeong

2022

Materials

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Practical Approach to Eliminate Solidification Cracks by Supplementing AlMg4.5Mn0.7 with AlSi10Mg Powder in Laser Powder Bed Fusion

Cited by 10 publications

References 43 publications

Study on mechanism of refining and modifying in Al–Si–Mg casting alloys with adding rare earth cerium

Study on mechanism of refining and modifying in Al–Si–Mg casting alloys with adding rare earth cerium

Influence of Novel Beam Shapes on Laser-Based Processing of High-Strength Aluminium Alloys on the Basis of EN AW-5083 Single Weld Tracks

Emerging Materials for Additive Manufacturing

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