In order to obtain high-performance aluminum alloy parts fabricated by selective laser melting, this paper investigates the relationship between the process parameters and microstructure properties of AlSi10Mg. The appropriate process parameters are obtained: the layer thickness is 0.03 mm, the laser power is 370 W, the scanning speed is 1454 mm/s, and the hatch spacing is 0.16 mm. With these process parameters, the ultimate tensile strength of the as-printed status is 500.7 ± 0.8 MPa, the yield strength is 311.5 ± 5.9 MPa, the elongation is 7.7 ± 0.5%, and the relative density is 99.94%. After annealing treatment at 275 °C for 2 h, the ultimate tensile strength is 310.8 ± 1.3 MPa, the yield strength is 198.0 ± 2.0 MPa, and the elongation is 13.7 ± 0.6%. The mechanical properties are mainly due to the high relative density, supersaturate solid solution, and fine dispersed Si. The supersaturate solid solution and nano-sized Si formed by the high cooling rate of SLM. After annealing treatment, the Si have been granulated and grown significantly. The ultimate tensile strength and yield strength are reduced, and the elongation is significantly improved.

In this paper, the cracking of Al-Mn-Mg-Sc-Zr alloys prepared by selective laser melting (SLM) was comprehensively explored and the influence of process parameters on the generation and propagation of cracks was deeply studied. It was found that the higher laser power and volume energy density will lead to a decrease in the relative density of the material. The lower laser power or volume energy density will lead to cracking of the alloy. The microstructure analysis indicated that plenty of manganese-rich second phases precipitated at the bottom of the melt pool, which increased the tendency of cracking occurred at the bottom of the melt pool. Through the optimization of the process parameters, the SLM forming process parameters of the Al-5.22Mn-1.16Mg-0.81Sc-0.46Zr alloy are successfully obtained, and the crack-free tensile samples are prepared. The microstructure and mechanical properties of the as-deposited aluminum-manganese alloy is analyzed. The bottom and inside of the melt pool are equiaxed grains. The size of the equiaxial grains at the bottom of the melt pool is less than 2 μm, and the coarse equiaxial grains inside the melt pool are approximately 5 μm. As-deposited alloy has a room temperature tensile strength of 455.2 ± 0.7 MPa and elongation of 15.4 ± 0.3%. This study provides guidance for selective laser melting forming of high-strength aluminum-manganese alloy parts, and promotes the industrial production of high-strength aluminum alloy near net forming complex parts.

In this paper, micron-sized TiB2/AlZnMgCu(Sc,Zr) composites were fabricated by selective laser melting (SLM) using directly mixed powder. Nearly fully dense (over 99.5%) and crack-free SLM-fabricated TiB2/AlZnMgCu(Sc,Zr) composite samples were obtained and its microstructure and mechanical properties were investigated. It is found that the laser absorption rate of powder is improved by introducing micron-sizedTiB2 particles, then the energy density required for SLM forming can be reduced, and the densification can finally be improved. Some crystalline TiB2 formed a coherent relationship with the matrix, while some broken TiB2 particles did not, however, MgZn2 and Al3(Sc,Zr) can perform as intermediate phases to connect these non-coherent surfaces to aluminum matrix. All these factors lead to an increase in strength of the composite. The SLM-fabricated micron-sized TiB2/AlZnMgCu(Sc,Zr) composite finally shows a very high ultimate tensile strength of ~646 MPa and yield strength of ~623 MPa, which are higher than many other aluminum composites fabricated by SLM, while maintaining a relatively good ductility of ~4.5%. The fracture of TiB2/AlZnMgCu(Sc,Zr) composite is occurred along the TiB2 particles and the bottom of the molten pool. This is due to the concentration of stress from the sharp tip of TiB2 particles and the coarse precipitated phase at the bottom of the molten pool. The results show that TiB2 plays a positive role in AlZnMgCu alloys fabricated by SLM, but finer TiB2 particles should be studied.

Selective laser melting (SLM) offers obvious advantages in the production of complex parts. However, the traditional 7xxx series aluminum alloy has a serious cracking tendency in the SLM process. Therefore, in order to analyze the microstructure and cracking mechanism, and obtain crack-free aluminum alloy fabricated by SLM, this paper studied the microstructure characteristics of as-deposited Al-6.2Zn-2Mg-xSc-xZr alloy with different Sc, Zr content, as well as the influence mechanism of Sc, Zr on cracking. The results show that with the increase of Sc and Zr content, the crack tendency and grain size decrease. When Sc and Zr content reach 0.6% and 0.36% respectively, cracks can no longer be observed in the as deposited alloy. The microstructure of the as deposited Al-6.2Zn-2Mg-0.6Sc-0.36Zr alloy consists of fine equiaxed and columnar crystals, in which Sc and Zr mainly exist in the aluminum matrix as solid solutions, and some exist in the form of Al3(Sc, Zr). The immediate reason for the absence of cracks is that the microstructure changes from coarse columnar grains to fine equiaxed-columnar grains when the content of Sc and Zr increases. The refined grain size may have the following beneficial effects: It helps with reducing the thickness of the liquid films. This will increase the tear sensitivity of the liquid film and the cracking tendency and therefore lowers the hot cracking tendency; And a refined grain size improves fracture roughness, leading to an enhanced cracking resistance. At the same time, the refinement of the grains will make the feeding channel of the grain boundary shorter and easy to feed, and the fine equiaxed grains can coordinate stress-strain during solidification more effectively than coarse columnar grains, which will decrease the cracking tendency.

High-entropy alloy (HEA) is a new type of multi-principal alloy material and the Hf-Nb-Ta-Ti-Zr HEAs have attracted more and more attention from researchers due to their high melting point, special plasticity, and excellent corrosion resistance. In this paper, in order to reduce the density of the alloy and maintain the strength of the Hf-Nb-Ta-Ti-Zr HEAs, the effects of high-density elements Hf and Ta on the properties of HEAs were explored for the first time based on molecular dynamics simulations. A low-density and high-strength Hf0.25NbTa0.25TiZr HEA suitable for laser melting deposition was designed and formed. Studies have shown that the decrease in the proportion of Ta element reduces the strength of HEA, while the decrease in Hf element increases the strength of HEA. The simultaneous decrease in the ratio of Hf and Ta elements reduces the elastic modulus and strength of HEA and leads to the coarsening of the alloy microstructure. The application of laser melting deposition (LMD) technology refines the grains and effectively solves the coarsening problem. Compared with the as-cast state, the as-deposited Hf0.25NbTa0.25TiZr HEA obtained by LMD forming has obvious grain refinement (from 300 μm to 20–80 μm). At the same time, compared with the as-cast Hf0.25NbTa0.25TiZr HEA (σs = 730 ± 23 MPa), the as-deposited Hf0.25NbTa0.25TiZr HEA has higher strength (σs = 925 ± 9 MPa), which is similar to the as-cast equiatomic ratio HfNbTaTiZr HEA (σs = 970 ± 15 MPa).

Fully dense and crack-free Al-Zn-Mg alloys with Sc and Zr additions were successfully fabricated by selective laser melting. The microstructures of as-built alloys with different Sc and Zr additions were characterized by scanning electron microscopy and transmission electron microscopy. The microstructure was composed of coarse columnar grains without Sc and Zr additions. In contrast, a fine heterogeneous microstructure, consisting of equiaxed grains at the bottom of the melt pool and columnar grains in the remaining volumes, was formed by adding 0.6 wt.% Sc and 0.26 wt.% Zr. In addition, a high density of precipitates was identified as η’ and I-phases that were distributed at grain boundaries and inside grains.