The Use of Selective Laser Melting to Increase the Performance of AlSi9Cu3Fe Alloy

Fousová, Michaela; Dvorský, Drahomír; Vronka, Marek; Vojtěch, Dalibor; Lejček, Pavel

doi:10.3390/ma11101918

Cited by 29 publications

(33 citation statements)

References 45 publications

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“…That is, a material which has a good strength-ductility balance can be produced by using SLM. Similar results have been reported in previous studies and have been explained by the microstructure specific to SLM [11,30]. Using SLM with the Base alloy did not dramatically increase the high-temperature strength; however, the Base + 3Fe and Base + 5Fe alloys were strengthened by SLM because of the addition of Fe.…”

Section: Resultssupporting

confidence: 90%

“…That is, a material which has a good strength-ductility balance can be produced by using SLM. Similar results have been reported in previous studies and have been explained by the microstructure specific to SLM [11,30]. The UTS and the EL at 300 °C of the sample prepared in this study and the novel cast Al alloys recently reported [25][26][27][28] are summarized in Table 3.…”

Section: Resultssupporting

confidence: 89%

“…The microstructure of these alloys features a half-cylindrical melt pool [4,6] and a eutectic Si cellular structure [4][5][6][7] formed by quenching solidification due to the repeated laser scanning melting and solidification. This unique microstructure makes the room-temperature strength of SLM alloys higher than that of cast Al alloys [10,11] or Al alloys made by powder metallurgy [12]. The improvement of the room-temperature strength of Al alloys by SLM has been explained by the cellular structure of fine Si particles [12].…”

Section: Introductionmentioning

confidence: 99%

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Effect of Fe Addition on Heat-Resistant Aluminum Alloys Produced by Selective Laser Melting

Yamasaki

Okuhira

Mitsuhara

et al. 2019

Metals

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The effect of Fe addition on the high-temperature mechanical properties of heat-resistant aluminum alloys produced by selective laser melting (SLM) was investigated in relation to the alloy microstructures. Fe is generally detrimental to the properties of cast aluminum alloys; however, we found that Fe-containing alloys produced by SLM had improved high-temperature strength and good ductility. Microstructural observations revealed that the increase in the high-temperature strength of the alloys was due to the dispersion of fine rod-shaped Fe-Si-Ni particles unique to the SLM material instead of the cell-like structure of eutectic Si.

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Section: Resultssupporting

confidence: 90%

“…That is, a material which has a good strength-ductility balance can be produced by using SLM. Similar results have been reported in previous studies and have been explained by the microstructure specific to SLM [11,30]. The UTS and the EL at 300 °C of the sample prepared in this study and the novel cast Al alloys recently reported [25][26][27][28] are summarized in Table 3.…”

Section: Resultssupporting

confidence: 89%

Section: Introductionmentioning

confidence: 99%

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Effect of Fe Addition on Heat-Resistant Aluminum Alloys Produced by Selective Laser Melting

Yamasaki

Okuhira

Mitsuhara

et al. 2019

Metals

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“…These include casting alloys like AlSiCu alloys (EN AC-46xxx and EN AC-47xxx). These alloys offer high tensile strengths of up to 500 MPa with a low elongation at break of 5% [5][6][7].Many known alloys are difficult to process by laser powder bed fusion due to the formation of pores and cracks during solidification. These include medium and high strength wrought alloys of the alloy systems AlCu (EN AW-2xxx) [8][9][10], AlMgSi (EN AW-6xxx) [11,12], and AlZnMg (EN AW-7xxx) [13][14][15].…”

mentioning

confidence: 99%

“…These include casting alloys like AlSiCu alloys (EN AC-46xxx and EN AC-47xxx). These alloys offer high tensile strengths of up to 500 MPa with a low elongation at break of 5% [5][6][7].…”

mentioning

confidence: 99%

A Tailored AlSiMg Alloy for Laser Powder Bed Fusion

Knoop

Lutz

Mais³

et al. 2020

Metals

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The majority of aluminum alloys used for laser powder bed fusion are based on the aluminum-silicon system, particularly alloys containing 7 to 12 wt.% silicon and less than 1 wt.% magnesium. Silicon has a beneficial influence on melt viscosity during casting and laser additive manufacturing and prevents the formation of cracks. This study focused on the development of a new AlSi3.5Mg2.5 alloy for laser powder bed fusion with a Mg-Si content above 1.85 wt.% Mg 2 Si, which is the solubility limit of the α-aluminum matrix, and a subsequent heat treatment to adjust the mechanical properties with a wide range of strength and ductility values. The characterization of the microstructure was conducted by optical microscopy, scanning electron microscopy, transmission electron microscopy, and differential scanning calorimetry. The mechanical properties were determined by tensile tests and additional tight radius bending tests. The newly developed alloy was compared with AlSi10Mg and Scalmalloy ® . AlSi3.5Mg2.5 offers higher strength and ductility than AlSi10Mg, at comparable material costs. The mechanical properties can be adjusted in a wide range of values using a single step heat treatment. After direct ageing, the samples exhibited a ultimate tensile strength (UTS) of 484 ± 1 MPa and an elongation at break of 10.5% ± 1.3%, while after soft annealing, they exhibited a UTS of 179 ± 2 MPa and an elongation at break of 25.6% ± 0.9%.Metals 2020, 10, 514 2 of 13 coarsen [1,2]. Currently, there are only a few alternative processable aluminum alloys for additive manufacturing. These include casting alloys like AlSiCu alloys (EN AC-46xxx and EN AC-47xxx). These alloys offer high tensile strengths of up to 500 MPa with a low elongation at break of 5% [5][6][7].Many known alloys are difficult to process by laser powder bed fusion due to the formation of pores and cracks during solidification. These include medium and high strength wrought alloys of the alloy systems AlCu (EN AW-2xxx) [8][9][10], AlMgSi (EN AW-6xxx) [11,12], and AlZnMg (EN AW-7xxx) [13][14][15]. Known structural concepts for the development of alloys that are adapted to the additive manufacturing process use rare earth elements, such as scandium and zirconium, with varying content [16][17][18] or feature the addition of nanoscale grain refining additives to the known wrought alloys, such as the alloy EN AW-7075 [19]. When processed by laser additive manufacturing, both approaches lead to a combination with a high strength above 500 MPa combined with a good elongation at break of up to 15%. The disadvantages of these approaches are the high costs of scandium and the application of nanoparticles. A more detailed review of investigations into aluminum alloys for the LPBF process can be found in [20,21].The use of EN AW-6xxx alloys, whose strength is based on precipitation hardening, promises medium strength with a smaller decrease in ductility at low material costs. Artificial ageing leads to the formation of magnesium/silicon precipitates, which hinder dislocation mo...

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Correlation Among Microstructure, Mechanical Properties, and Thermal Stability of a Novel HPDC Al–12Si Alloy with Minor Sc

et al. 2022

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The microstructure, mechanical properties, and thermal stability of high‐pressure die casting (HPDC) Al–12Si–Sc alloy with 0.1 wt% Sc addition are investigated. Compared with the commercial A380 alloy, the alloy shows a significant refinement of α‐Al and eutectic Si microstructure. Meanwhile, β‐Fe with irregular morphology shows a smaller size and lower volume fraction in Al–12Si–Sc alloy. Upon as‐cast state, the elongation of the alloy is improved to 6.7% with an ultimate tensile strength of 332 MPa, which is a better combination of ductility and strength in the literature. After thermal exposure at 200 °C for 200 h, it retains tensile strength of 277 MPa and holds the microhardness up to 90 HV even exposure for 1000 h. These excellent properties may widen the application of HPDC Al–Si alloy for the cylinder block and cylinder head.

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The Use of Selective Laser Melting to Increase the Performance of AlSi9Cu3Fe Alloy

Cited by 29 publications

References 45 publications

Effect of Fe Addition on Heat-Resistant Aluminum Alloys Produced by Selective Laser Melting

Effect of Fe Addition on Heat-Resistant Aluminum Alloys Produced by Selective Laser Melting

A Tailored AlSiMg Alloy for Laser Powder Bed Fusion

Correlation Among Microstructure, Mechanical Properties, and Thermal Stability of a Novel HPDC Al–12Si Alloy with Minor Sc

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