The latest development of Sc-strengthened aluminum alloys by laser powder bed fusion

Bayoumy, Dina; Kan, Wenhao; Wu, Xinhua; Zhu, Yuman; Huang, Aijun

doi:10.1016/j.jmst.2022.11.028

Cited by 24 publications

(11 citation statements)

References 108 publications

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“…The average grain sizes of the equiaxed grains in the FEGB, CEGB, and EGT regions are about 1.0 μm, 1.9 μm, and 16.0 μm, respectively. The grain structure of the AMed AlMgMnSc aluminium alloy is primarily determined by the solidification condition of the melting pool and precipitation of primary The grain structure of the AMed AlMgMnSc aluminium alloy is primarily determined by the solidification condition of the melting pool and precipitation of primary Al 3 (Sc, Zr) particles [37]. During solidification, a high temperature gradient (G) at the solidification interface and low solidification velocity (V) favour the formation of columnar grains growing along the direction parallel to the direction of the maximum thermal gradient.…”

Section: Resultsmentioning

confidence: 99%

“…Additionally, primary Al 3 (Sc, Zr) particles tend to precipitate from liquid metals before the onset of α-Al solidification. The similar lattice constants of α-Al and Al 3 (Sc, Zr) make the Al 3 (Sc, Zr) particles effective nucleation cores for the following solidification of α-Al grains [37]. As a result, the formation of a fine equiaxed grain structure is strongly promoted.…”

Section: Resultsmentioning

confidence: 99%

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Microstructure and Microhardness of High-Strength Aluminium Alloy Prepared Using High-Speed Laser Fabrication

Wu,

Chen,

et al. 2024

Metals

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As a recently developed high-strength aluminium alloy used specifically for laser additive manufacturing, AlMgMnSc alloy possesses superior mechanical properties and excellent processability. Extreme high-speed laser deposition (EHLD) is a novel surface-modification technique, which is characterised by high depositing speed, rapid cooling, rate and minimal dilution rate. To offer a new method for surface repairing high-strength aluminium alloys, an AlMgMnSc alloy coating, containing two deposition layers, is prepared on a 6061 aluminium-alloy axle using the EHLD technique. Meanwhile, the microstructure, composition distribution, and microhardness variation of the fabricated coating are studied. The results reveal that the coating is dense and crack-free, which is well-bonded with the substrate. Additionally, layer 1 is mainly composed of large columnar and equiaxed grains, while layer 2 consists of a fully equiaxed grain structure with an average grain size of about 4.5 μm. Moreover, the microhardness of the coating (about 104~118 HV) is similar to the substrate (about 105 HV), proving the feasibility of repairing high-strength aluminium alloys using AlMgMnSc alloy powders through the EHLD technique.

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Section: Resultsmentioning

confidence: 99%

Section: Resultsmentioning

confidence: 99%

Microstructure and Microhardness of High-Strength Aluminium Alloy Prepared Using High-Speed Laser Fabrication

Wu,

Chen,

et al. 2024

Metals

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“…Compared to other AM technologies, LPBF can achieve a better surface finish and dimensional accuracy [4]. The interest in LPBF-fabricated Al alloys is growing to meet the high demand for critical lightweight structural components for a wide range of applications, such as space, aerospace, and automotive tools and equipment [5][6][7].…”

Section: Introductionmentioning

confidence: 99%

“…In addition, the rapidly solidifying tracks result in a highly supersaturated solid solution. A much higher degree of solute supersaturation within the Al matrix can be achieved compared to conventional processing [5]. Subsequently, Al alloys can be solid-solution-strengthened and precipitationhardened to unprecedented high degrees, which improve the part's functional performance.…”

Section: Introductionmentioning

confidence: 99%

Effective Platform Heating for Laser Powder Bed Fusion of an Al-Mn-Sc-Based Alloy

Bayoumy,

Boll,

Karapuzha

et al. 2023

Materials

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Platform heating is one of the effective strategies used in laser powder bed fusion (LPBF) to avoid cracking during manufacturing, especially when building relatively large-size components, as it removes significant process-induced residual strains. In this work, we propose a novel and simple method to spare the elaborate post-processing heat treatment typically needed for LPBF Al-Sc alloys without compromising the mechanical properties. We systematically investigated the effects of LPBF platform heating at 200 °C on the residual stress relief, microstructure, and mechanical performance of a high-strength Al-Mn-Sc alloy. The results reveal that LPBF platform heating at 200 °C is sufficient to largely relieve the process-induced residual stresses compared to parts built on an unheated 35 °C platform. Meanwhile, the platform heating triggered the dynamic precipitation of uniformly dispersed (1.5–2 nm) Sc-rich nano-clusters. Their formation in a high number density (1.75 × 1024 m−3) resulted in a ~20% improvement in tensile yield strength (522 MPa) compared to the build on the unheated platform, without sacrificing the ductility (up to 18%). The improved mechanical properties imply that platform heating at 200 °C can strengthen the LPBF-synthesised Sc-containing Al alloys via in situ aging, which is further justified by an in situ measurement study revealing that the developing temperatures in the LPBF part are within the aging temperature range of Al-Sc alloys. Without any post-LPBF treatments, these mechanical properties have proven better than those of most Al-Sc alloys through long-time post-LPBF heat treatment.

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“…However, the suggestion of the mechanism relating to remelting seems to be still prevailing as described in a recent review on the progress of aluminum‐alloy LPBF [ 24 ] and in a review specifically on LPBF of Sc‐containing aluminum alloys. [ 25 ] Recently, Ekubaru et al [ 23 ] demonstrated that controlling hatch spacing can control the amount of equiaxed grains and thus can control the strength of the alloy through grain‐boundary strengthening. A recent effort on the alloy design for microstructure control in LPBF of aluminum alloys also was centered on the modification of the alloys using Sc.…”

Section: Introductionmentioning

confidence: 99%

On the Mechanism of Formation of Bimodal Grain Structure in Al–4.5Mg–0.7Sc–0.3Zr Alloy Processed by Laser Powder Bed Fusion

Chernyshova¹,

Guraya

Martínez-Amesti

et al. 2023

Adv Eng Mater

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Scalmalloy is an Al–Mg alloy with additions of Sc and Zr originally developed as a high‐strength aluminum alloy with σ0.2 ≥ 450 MPa for aerospace industry. It is now well understood that the alloy is amendable for processing by laser powder bed fusion (LPBF). However, the mechanism of formation of the equiaxed‐columnar bimodal grain structure during LPBF is not ascertained yet, fully. Herein, this gap is addressed with special focus on the distributions of critical elements such as Sc and various particles that form during LBPF. It is found that strong and weak segregation of Mg and Sc, respectively, occurs in the final solidification areas of the fine‐ and equiaxed‐grain regions. The coarser and columnar grain regions show weak segregation of Mg and no Sc segregation. A priori knowledge on the Al–Sc eutectic reaction, its dependence on cooling rates, and the well‐known thermal and solidification conditions related to the track location during LPBF is used to ascertain the mechanism of formation of the bimodal grain structure. The mechanism suggested is substantiated by the location‐dependent elemental distributions and the various particles that are observed.

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The latest development of Sc-strengthened aluminum alloys by laser powder bed fusion

Cited by 24 publications

References 108 publications

Microstructure and Microhardness of High-Strength Aluminium Alloy Prepared Using High-Speed Laser Fabrication

Microstructure and Microhardness of High-Strength Aluminium Alloy Prepared Using High-Speed Laser Fabrication

Effective Platform Heating for Laser Powder Bed Fusion of an Al-Mn-Sc-Based Alloy

On the Mechanism of Formation of Bimodal Grain Structure in Al–4.5Mg–0.7Sc–0.3Zr Alloy Processed by Laser Powder Bed Fusion

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