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Special Issue "Aluminium Alloys for Additive Manufacturing: Alloy Development, Structures, Properties and Applications"

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Guest Editor

School of Mechanical and Electrical Engineering, Soochow University, Suzhou 215131, China
Interests: additive manufacturing; physical metallurgy; mcirostructure; mechanical property

Dr. Xiaopeng Li

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Guest Editor

School of Mechanical and Manufacturing Engineering, The University of New South Wales (UNSW Sydney), Sydney, NSW 2052, Australia
Interests: additive manufacturing; metals and alloys; machine learning; medical device

Special Issue Information

Dear Colleagues,

Additive manufacturing offers the unique capability of improving the sustainability of metallic components production by reducing the need for tooling, machining and assembling. The application of aluminium alloys for additive manufacturing has further pushed the high-strength and lightweight limits of this field through innovative structure design and integrated fabrication. However, significant challenges in the areas of alloy processability, mechanical property and available alloys are still associated with this process, which needs to be addressed with further research efforts.

This Special Issue focus on the structures and properties of additively manufactured aluminum alloys. Research efforts in the field of novel alloy development, process optimization, structure, property and applications are all welcome.

Dr. Qingbo Jia
Dr. Xiaopeng Li
Guest Editors

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Keywords

additive manufacturing
aluminium alloys
alloy development
micro- and macro-structures
properties
applications

Published Papers (3 papers)

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Research

12 pages, 14714 KiB

Open AccessArticle

High-Throughput Printability Screening of AlMgSi Alloys for Powder Bed Fusion

Freddy Leijon

and

Johan Moverare

Metals 2023, 13(6), 1114; https://doi.org/10.3390/met13061114 - 13 Jun 2023

Viewed by 743

Abstract

The importance of both recycling and additive manufacturing (AM) is increasing; however, there has been a limited focus on the development of AM alloys that are compatible in terms of recyclability with the larger scrap loops of wrought 5xxx, 6xxx and cast 3xx aluminium alloys. In this work, the powder bed fusion (PBF) printability of AlMgSi alloys in the interval of 0–30 wt% Mg and 0–4 wt% Si is screened experimentally with a high-throughput method. This method produces PBF-mimicked material by PVD co-sputtering, followed by laser remelting. Strong evidence was found for AlMgSi alloys being printable within two different composition ranges: Si + Mg < 0.7 wt% or for Si + 2/3 Mg > 4 wt% when Mg < 3 wt% and Si > 3 wt%. Increasing the amount of Mg and Si influences the grain structure by introducing fine columnar grains at the melt pool boundary, although the melt pool interior was unaffected. Hardness in an as-built state increased with both Mg and Si, although Si had a neglectable effect at low levels of Mg. Both the evaporative loss of Mg and the amount of Mg in solid solution increased linearly with the amount of Mg. Full article

(This article belongs to the Special Issue Aluminium Alloys for Additive Manufacturing: Alloy Development, Structures, Properties and Applications)

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16 pages, 7806 KiB

Open AccessArticle

Microstructures and High Temperature Tensile Behaviours of Laser Powder Bed Fusion Fabricated Al-Mn-Sc Alloy

and

Metals 2023, 13(4), 788; https://doi.org/10.3390/met13040788 - 17 Apr 2023

Viewed by 710

Abstract

The introduction of Sc/Zr inoculates to aluminium (Al) alloys for laser powder bed fusion (LPBF) provides numerous benefits, including laser processability improvement, solidification microstructure control and mechanical property enhancement. Though great efforts have been put into tailoring the microstructure and room temperature mechanical properties via process parameter optimisations, the potential roles of Sc/Zr inoculate modified Al alloys for high-temperature applications were still underexplored. In this study, the microstructural stability and the elevated temperature tensile behaviours of LPBF-processed Al-Mn-Sc alloy were systematically evaluated. The alloy demonstrated high microstructural stability after both heat treatment and high-temperature tensile testing for up to 573 K. The applied tensile testing temperature and strain rate played significant influences on the elevated temperature tensile properties and deformation behaviours. Unusual intermediate temperature embrittlement (also known as ductility dip) and yield drop behaviours were observed under certain testing temperature and strain rate regimes, and the underlying deformation mechanisms were elucidated in detail. The present study is expected to shed light on future high-performance, high-temperature Al alloy development for the LPBF process. Full article

(This article belongs to the Special Issue Aluminium Alloys for Additive Manufacturing: Alloy Development, Structures, Properties and Applications)

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13 pages, 4100 KiB

Open AccessArticle

Process Optimization for Up-Facing Surface Finish of AlSi10Mg Alloy Produced by Laser Powder Bed Fusion

and

Metals 2022, 12(12), 2053; https://doi.org/10.3390/met12122053 - 29 Nov 2022

Cited by 1 | Viewed by 1157

Abstract

This work investigates the effects of various processing parameters (laser power, scanning speed, hatch distance and beam offset) on the resultant inclined up-facing surface roughness of AlSi10Mg alloys produced by laser powder bed fusion (LPBF). A two-step approach, orthogonal test followed by the Doehlert matrix design (DMD) test is used to efficiently optimize the up-facing surface and contour parameters. The former method aims to determine the significance of variables while the latter one facilitates a rapid optimization. The results show that the interaction and interdependency among the parameters are of great significance to the obtainable surface roughness. Using a rational design of experiments, the optimized up-facing surface roughness of Ra of 5.4 μm is achieved. This is attributed to the elimination of the laser partition track and the reduction in irregularities at the edges of the parts. This work demonstrates an effective approach of experimental processing parameter optimization to improve the surface finish of LPBF parts. Full article

(This article belongs to the Special Issue Aluminium Alloys for Additive Manufacturing: Alloy Development, Structures, Properties and Applications)

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