Assessment of AlZnMgCu alloy powder modification for crack-free laser powder bed fusion by differential fast scanning calorimetry

Zhuravlev, Evgeny; Milkereit, Benjamin; Yang, Bin; Heiland, Steffen; Vieth, Pascal; Voigt, Markus; Schaper, Mirko; Grundmeier, Guido; Schick, Christoph; Keßler, Olaf

doi:10.1016/j.matdes.2021.109677

Cited by 24 publications

(19 citation statements)

References 43 publications

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“…DFSC measurements require careful temperature correction related to suitable reference temperatures. Details on measurement and evaluation have been published in [ 5 ]. Figure 2 b shows three typical DFSC heating and cooling curves on alloy 2024 at a rate of 10 4 K/s without and with CaB 6 nanoparticles.…”

Section: Methodsmentioning

confidence: 99%

“…Therefore, we analyse the rapid melting/solidification behaviour of the modified powders in-situ by calorimetry. Especially differential fast scanning calorimetry (DFSC) with sample sizes of a few 10 µm particles (equivalent to PBF-LB/M powder particle sizes) and heating/cooling rates of up to 10 6 K/s (equivalent to PBF-LB/M processes) is a suitable method [ 5 ]. In detail, rapid solidification conditions of single powder particles by DFSC differ from those in PBF-LB/M melt pools with dimensions in the several 100 µm ranges, where numerous powder particles are molten simultaneously.…”

Section: Introductionmentioning

confidence: 99%

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Correlation between Differential Fast Scanning Calorimetry and Additive Manufacturing Results of Aluminium Alloys

et al. 2022

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High-strength aluminium alloy powders modified with different nanoparticles by ball milling (7075/TiC, 2024/CaB6, 6061/YSZ) have been investigated in-situ during rapid solidification by differential fast scanning calorimetry (DFSC). Solidification undercooling has been evaluated and was found to decrease with an increasing number of nanoparticles, as the particles act as nuclei for solidification. Lower solidification undercooling of individual powder particles correlates with less hot cracking and smaller grains in the material produced by powder bed fusion of metals by a laser beam (PBF-LB/M). Quantitatively, solidification undercooling less than about 10–15 K correlates with almost crack-free PBF-LB/M components and grain sizes less than about 3 µm. This correlation shall be used for future purposeful powder material design on small quantities before performing extensive PBF-LB/M studies.

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Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Correlation between Differential Fast Scanning Calorimetry and Additive Manufacturing Results of Aluminium Alloys

et al. 2022

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“…Three measurements were performed with the small ring shear cell M1 (V = 31 cm 3 ). The details on all experimental aspects of the DFSC analysis including temperature correction are published by Zhuravlev et al [ 43 ].…”

Section: Methodsmentioning

confidence: 99%

Requirements for Processing High-Strength AlZnMgCu Alloys with PBF-LB/M to Achieve Crack-Free and Dense Parts

et al. 2021

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Processing aluminum alloys employing powder bed fusion of metals (PBF-LB/M) is becoming more attractive for the industry, especially if lightweight applications are needed. Unfortunately, high-strength aluminum alloys such as AA7075 are prone to hot cracking during PBF-LB/M, as well as welding. Both a large solidification range promoted by the alloying elements zinc and copper and a high thermal gradient accompanied with the manufacturing process conditions lead to or favor hot cracking. In the present study, a simple method for modifying the powder surface with titanium carbide nanoparticles (NPs) as a nucleating agent is aimed. The effect on the microstructure with different amounts of the nucleating agent is shown. For the aluminum alloy 7075 with 2.5 ma% titanium carbide nanoparticles, manufactured via PBF-LB/M, crack-free samples with a refined microstructure having no discernible melt pool boundaries and columnar grains are observed. After using a two-step ageing heat treatment, ultimate tensile strengths up to 465 MPa and an 8.9% elongation at break are achieved. Furthermore, it is demonstrated that not all nanoparticles used remain in the melt pool during PBF-LB/M.

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“…The power of the diode laser can be precisely adjusted from zero to about 100 mW. Thus, the power compensation scheme makes it possible to control the sample temperature during laser heating in the same way as during membrane heating [19]. In the case of laser heating, we have gained the advantage of local heating with simultaneous local temperature measurement.…”

Section: Laser Heatingmentioning

confidence: 99%

“…The measured microdroplet is commonly heated by a thin film heater located on the calorimeter membrane (membrane heating). However, the microdroplet can alternatively be heated by an external diode laser (laser heating) [19]. Our goal is to measure interfacial heat transfer between metal microdroplets and a substrate during fast melting and solidification at a temperature scan rate in the range from 10 3 K s −1 to 10 5 K s −1 .…”

Section: Introductionmentioning

confidence: 99%

Interfacial thermal conductance of 7075 aluminum alloy microdroplets in contact with a solid at fast melting and crystallization

Минаков

Morikawa

Ryu

et al. 2022

Mater. Res. Express

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Ultrafast nanocalorimetry, in combination with high-speed IR thermography, is used to measure the interfacial thermal conductance (ITC) of the thermal contact of metal microdroplets with a solid during fast melting (including laser heating). IR thermography and membrane nanocalorimetry were used to measure the temperature difference at the membrane/sample interface during the melting and crystallization of aluminium alloy (AA7075) microdroplets (20 μm in diameter) over a wide range of heating and cooling rates (up to 105 K/s). This is the first time ITC has been measured at such high heating and cooling rates with this new method. We found that the interfacial temperature difference reaches about 80 K during the solidification of microdroplets during laser heating. This result is significant for understanding various industrial laser-assisted processes. It has been established that ITC measured for AA7075 microdroplets gradually increases by an order of magnitude during melting in the range from the solidus temperature to the liquidus temperature of the alloy. This unusual behavior of ITC during melting can be important for understanding and optimizing laser-assisted additive manufacturing processes.

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Assessment of AlZnMgCu alloy powder modification for crack-free laser powder bed fusion by differential fast scanning calorimetry

Cited by 24 publications

References 43 publications

Correlation between Differential Fast Scanning Calorimetry and Additive Manufacturing Results of Aluminium Alloys

Correlation between Differential Fast Scanning Calorimetry and Additive Manufacturing Results of Aluminium Alloys

Requirements for Processing High-Strength AlZnMgCu Alloys with PBF-LB/M to Achieve Crack-Free and Dense Parts

Interfacial thermal conductance of 7075 aluminum alloy microdroplets in contact with a solid at fast melting and crystallization

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