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Densification, Microstructural, and Mechanical Properties of Al-Mn-Mg-Er-Zr Alloy Fabricated by Laser Powder Bed Fusion

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Abstract

To address the high cost of raw materials for laser powder bed fusion (L-PBF) processed high-performance Al-Mn-Mg-Sc-Zr alloy, a novel Er- and Zr-modified Al-Mn-Mg alloy was fabricated by L-PBF using pre-alloyed powder in this study. The large internal stress and the existence of the keyhole together caused cracks in most of the L-PBF processed samples. The as-built sample exhibited a heterogeneous grain structure, including main columnar α-Al grains in the inner region of the molten pool and a few ultrafine α-Al equiaxed grains at the fusion boundary. Al3Er nanoparticles were attached to the Al6Mn phase, and both mainly precipitated at the grain boundary of α-Al. The existence of Mn in the alloy reduced the grain refining effect of Er elements. The yield strength (YS), ultimate tensile strength (UTS) and elongation of the as-built alloy were 327 ± 5 MPa, 502 ± 3 MPa, and 12.2 ± 1% respectively. When the aging temperature was over 350 ℃, the primary precipitates in the sample grew up, and needle-shaped secondary Al6Mn nanoparticles precipitated from α-Al. 350 ℃-6 h aging alloy exhibited maximum Vickers hardness of 171 ± 1 HV with YS, UTS and elongation of 339 ± 2 MPa, 508 ± 1 MPa and 8.1 ± 1%, respectively. During the tensile process of the alloy, micro-cracks mainly originated from the fusion boundary. At last, the authors also shared some prospects for future work.

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Acknowledgements

This research was supported by the Natural Science Foundation of China (Nos. 51801079 and 52001140) and the Portugal National Funds through FCT Project (2021.04115).

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Authors and Affiliations

  1. School of Materials Science and Engineering, Jiangsu University of Science and Technology, Zhenjiang, 212003, China

    Jiang Yu, Yaoxiang Geng, Zhijie Zhang & Hongbo Ju

  2. CEMMPRE-Centre for Mechanical Engineering Materials and Processes, Department of Mechanical Engineering, University of Coimbra, Rua Luís Reis Santos, 3030-788, Coimbra, Portugal

    Hongbo Ju

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Correspondence to Yaoxiang Geng.

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Yu, J., Geng, Y., Zhang, Z. et al. Densification, Microstructural, and Mechanical Properties of Al-Mn-Mg-Er-Zr Alloy Fabricated by Laser Powder Bed Fusion. Met. Mater. Int. 29, 3235–3248 (2023). https://doi.org/10.1007/s12540-023-01449-z

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