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The present work deals with the anisotropic high-strain rate behavior of laser-powder bed fusion (L-PBF) produced AlSi10Mg alloy in different heat treatment conditions. Impact specimens were produced with different orientations towards building platform and U-notch positions to assess the anisotropic properties. Besides the as-built material, several heat treatments were considered, including annealing, standard T6, hot isostatic pressing (HIP), HIP plus T6, and a recently proposed T6 at high pressure. The high-strain rate behavior was investigated by conducting Charpy impact tests, while material characterization was performed by scanning electron microscopy and x-ray diffraction. Results show that as-built and annealed alloys display significant anisotropic impact properties, whereas samples heat-treated at high temperatures generally have more consistent behavior. A coupled microstructural and fractographic investigation highlights that mitigation of anisotropy descends from the recovery of microstructural heterogeneity of the Si phase after heat treatment at high temperatures. This does not happen for both grain morphology or crystallographic structure, which are not significantly altered after the heat treatment. The present study aims to fill the gap in the literature regarding the anisotropic high-strain rate behavior of additively manufactured Al alloys and provide useful insights for mitigation of anisotropy by heat treatment.

In recent years, the influence of Ni on high-temperature mechanical properties of casting Al alloys has been extensively examined in the literature. In the present study, room temperature mechanical properties of an A356 alloy with Ni additions from 0.5 to 2 wt % were investigated. The role of Ni-based compounds and eutectic Si particles in reinforcing the Al matrix was studied with image analysis and was then related to tensile properties and microhardness. In the as-cast condition, the formation of the 3D network is not sufficient to determine an increase of mechanical properties of the alloys since fracture propagates by cleavage through eutectic Si particles and Ni aluminides or by the debonding of brittle phases from the aluminum matrix. After T6 heat treatment the increasing amount of Ni aluminides, due to further addition of Ni to the alloy, together with their brittle behavior, leads to a decrease of yield strength, ultimate tensile strength, and Vickers microhardness. Despite the fact that Ni addition up to 2 wt % hinders spheroidization of eutectic Si particles during T6 heat treatment, it also promotes the formation of a higher number of brittle Ni-based compounds that easily promote fracture propagation.

Thermal analysis is widely used as a prediction tool for the quality of Al alloys before casting. In the present work, the effects of different grain refiners on the characteristic temperatures and on the grain size of α-Al phase were studied by thermal analysis and metallographic investigations. The response of an AlSiMg alloy towards grain refiners, added in form of rods and tabs, was investigated. In foundry practice, the fading phenomenon of grain refiners is well-known but not completely understood. For these reasons, the fading effect of each refiner at 60 minutes and 120 minutes holding times was also studied. Cooling curves and their derivatives were obtained during solidification of the alloys in a metallic crucible. Experimental data indicated the increase of the temperature associated with the nucleation of α-Al dendrites for the grain-refined alloys in comparison to the untreated ones. Simultaneously, a decrease in primary Al growth temperature, that led to the disappearance of the minimum temperature, were observed. Microstructural features revealed that an increase of 6 ÷ 7 °C of the nucleation temperature, compared to the not refined alloy, corresponds to a significant decrease in average grain size.

In the present study the impact behavior of gravity casting AlSi10Mg alloy was evaluated with an instrumented Charpy pendulum. The effect of hot isostatic pressing, also followed by a T6 treatment, was analyzed in comparison with samples in the as-cast, annealed and T6 conditions. Furthermore, the effect of the innovative high-pressure T6 was investigated. It was found that the hot isostatic pressing is able to ensure densification of the alloy with an increase in both hardness and energy absorbed during impact. The T6 treatment performed at atmospheric pressure after the hot isostatic pressing is able to increase hardness and peak force. At the same time, the innovative high-pressure T6 is able to ensure similar results than those of hot isostatic pressing followed by T6, leading to a significant decrease in the treatment duration and costs and reducing the carbon footprint of the manufacturing process.