Experimental determination of cooling rates in selectively laser-melted eutectic Al-33Cu

Pauly, S.; Wang, Pei; Kühn, U.; Kosiba, Konrad

doi:10.1016/j.addma.2018.05.034

Cited by 70 publications

(47 citation statements)

References 31 publications

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“…By adding millions of scan tracks together, a part is formed. The application of a laser source for processing typically leads to rapid cooling and high temperature gradients in the range of (7 × 10 4 )-(4 × 10 7 ) K/s and (5 × 10 4 )-(5 × 10 6 ) K/m [6,7], respectively, compared to conventional manufacturing processes such as casting and forming. This thermal load leads to high stresses during solidification and cooling of the final component.…”

Section: Introductionmentioning

confidence: 99%

Grain Structure Evolution of Al–Cu Alloys in Powder Bed Fusion with Laser Beam for Excellent Mechanical Properties

Rasch¹,

Heberle

Dechet³

et al. 2019

Materials

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Powder Bed Fusion with Laser Beam of Metals (PBF-LB/M) is one of the fastest growing technology branches. More and more metallic alloys are being qualified, but processing of aluminum wrought alloys without cracks and defects is still challenging. It has already been shown that small parts with low residual porosity can be produced. However, suffering from microscopic hot cracks, the fracture behavior has been rather brittle. In this paper different combinations of temperature gradients and solidification rates are used to achieve specific solidification conditions in order to influence the resulting microstructure, as well as internal stresses. By this approach it could be shown that EN AW-2024, an aluminum-copper wrought alloy, is processable via PBF-LB/M fully dense and crack-free with outstanding material properties, exceeding those reported for commonly manufactured EN AW-2024 after T4 heat treatment.

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Section: Introductionmentioning

confidence: 99%

Grain Structure Evolution of Al–Cu Alloys in Powder Bed Fusion with Laser Beam for Excellent Mechanical Properties

Rasch¹,

Heberle

Dechet³

et al. 2019

Materials

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“…However, recently Pauly et al have demonstrated formation of a lamellar eutectic in an Al-33Cu alloy fabricated by SLM from gas atomized Al-33Cu powders [ 116 ]. The Al-33Cu composition shows a perfect lamellar eutectic microstructure.…”

Section: Microstructurementioning

confidence: 99%

“…The width of the lamellae may be adjusted by varying the cooling rate (i.e., by modifying the process parameters; especially laser power and laser scan speed). In addition, Pauly et al were able to demonstrate that the volumetric energy density is an inaccurate measure for inferring cooling rates, at least for this alloy [ 116 ].…”

Section: Microstructurementioning

confidence: 99%

Selective Laser Melting of Aluminum and Its Alloys

et al. 2020

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The laser-based powder bed fusion (LBPF) process or commonly known as selective laser melting (SLM) has made significant progress since its inception. Initially, conventional materials like 316L, Ti6Al4V, and IN-718 were fabricated using the SLM process. However, it was inevitable to explore the possible fabrication of the second most popular structural material after Fe-based alloys/steel, the Al-based alloys by SLM. Al-based alloys exhibit some inherent difficulties due to the following factors: the presence of surface oxide layer, solidification cracking during melt cooling, high reflectivity from the surface, the high thermal conductivity of the metal, poor flowability of the powder, low melting temperature, etc. Researchers have overcome these difficulties to successfully fabricate the different Al-based alloys by SLM. However, there exists no review dealing with the fabrication of different Al-based alloys by SLM, their fabrication issues, microstructure, and their correlation with properties in detail. Hence, the present review attempts to introduce the SLM process followed by a detailed discussion about the processing parameters that form the core of the alloy development process. This is followed by the current research status on the processing of Al-based alloys and microstructure evaluation (including defects, internal stresses, etc.), which are dealt with on the basis of individual Al-based series. The mechanical properties of these alloys are discussed in detail followed by the other important properties like tribological properties, fatigue properties, etc. Lastly, an outlook is given at the end of this review.

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“…Nowadays, additive manufacturing (AM) techniques, such as laser powder bed fusion (LPBF), provide the solution for overcoming this deficiency [ 5 ]. Since only small powder volumes are consecutively melted, high cooling rates (10 4 –10 6 K/s) are inherent to LPBF [ 6 ], which generally allows to process a wide variety of metallic glass forming alloys. The resulting BMGs are fabricated “layer-by-layer” with sheer unlimited geometrical freedom [ 5 , 7 , 8 ].…”

Section: Introductionmentioning

confidence: 99%

“…Only the relaxation behavior was investigated recently for Zr 52.5 Cu 17.9 Ni 14.6 Al 10 Ti 5 [ 9 ] and Zr 59.3 Cu 28.8 Nb 1.5 Al 10.4 [ 15 ] LPBF BMGs. Owing to the high cooling rates effective during LPBF [ 6 ], the corresponding BMGs show a lower atomic packing density readily reflected in larger relaxation enthalpies [ 9 ]. However, understanding the behavior of LPBF BMGs at elevated temperatures is of importance because they could be post-processed via thermoplastic forming (TPF) [ 18 , 19 , 20 ].…”

Section: Introductionmentioning

confidence: 99%

Viscous Flow of Supercooled Liquid in a Zr-Based Bulk Metallic Glass Synthesized by Additive Manufacturing

2020

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The constraint in sample size imposed by the critical cooling rate necessary for glass formation using conventional casting techniques is possibly the most critical limitation for the extensive use of bulk metallic glasses (BMGs) in structural applications. This drawback has been recently overcome by processing glass-forming systems via additive manufacturing, finally enabling the synthesis of BMGs with no size limitation. Although processing by additive manufacturing allows fabricating BMG objects with virtually no shape limitation, thermoplastic forming of additively manufactured BMGs may be necessary for materials optimization. Thermoplastic forming of BMGs is carried out above the glass transition temperature, where these materials behave as highly viscous liquids; the analysis of the viscosity is thus of primary importance. In this work, the temperature dependence of viscosity of the Zr52.5Cu17.9Ni14.6Al10Ti5 metallic glass fabricated by casting and laser powder bed fusion (LPBF) is investigated. We observed minor differences in the viscous flow of the specimens fabricated by the different techniques that can be ascribed to the higher porosity of the LPBF metallic glass. Nevertheless, the present results reveal a similar overall variation of viscosity in the cast and LPBF materials, which offers the opportunity to shape additively manufactured BMGs using already developed thermoplastic forming techniques.

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Experimental determination of cooling rates in selectively laser-melted eutectic Al-33Cu

Cited by 70 publications

References 31 publications

Grain Structure Evolution of Al–Cu Alloys in Powder Bed Fusion with Laser Beam for Excellent Mechanical Properties

Grain Structure Evolution of Al–Cu Alloys in Powder Bed Fusion with Laser Beam for Excellent Mechanical Properties

Selective Laser Melting of Aluminum and Its Alloys

Viscous Flow of Supercooled Liquid in a Zr-Based Bulk Metallic Glass Synthesized by Additive Manufacturing

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