On the Processability of Aluminium Alloys by PBF-L/M Additive Manufacturing Technology

Abstract:

The interest in aluminium alloys for Additive Manufacturing (AM) processes has increased significantly during the last years. Thanks to the freedom of design offered by AM technologies, specifically for Powder Bed Fusion – Laser/Metal (PBF-L/M), aluminium alloys have shown a high potential for their implementation in several industrial sectors. The combination of a reduced density together with high specific mechanical performance (e.g. Rp0.2 stress against density) and other materials properties, like a high thermal and electrical conductivity, or improved corrosion resistance, between others, make AM Al-alloys a great choice for the production of several applications, in particular for the aerospace industry. There are currently available several commercial Al-alloys in the market, although their maturity for producing final Al-products with the high quality required for the aerospace industry still need to be investigated. This paper explores the processability of different Al-alloys manufactured by PBF-L/M. This is analyzed by the development of a Design of Experiment (DoE) campaign for achieving the best processing parameters in order to produce full dense materials. There, bulk and surface density, void content and surface roughness are the main variables to be characterized at this initial step. Later, different thermal treatments are applied and evaluated for each alloy, aiming to produce the best mechanical characteristics, but also analysing other relevant aspects such the electrical resistivity and thermal conductivity.

• Periodical: Key Engineering Materials (Volume 958)
• Pages: 165-173
• DOI: https://doi.org/10.4028/p-2cjFcs
• Online since: October 2023
• Authors: Ignacio González-Barba*, Antonio Periñán, Javier Santaolaya, Álvaro Nieto, Carlos Galleguillos, Daniel Hervás, Fernando Lasagni
• Keywords: Additive Manufacturing, Al-Alloys, Characterization, Parametrization, PBF-L/M

References

[1] J. C. Bean, B. Laboratories, • B J Beaudry, • David, and F. Berry, "Volume 2 Publication Information and Contributors."

[2] F. Lasagni et al., "On the Processability and Mechanical Behavior of Al-Mg-Sc alloy for LPBF."

[3] Z. A. Young et al., "Types of spatter and their features and formation mechanisms in laser powder bed fusion additive manufacturing process," Addit Manuf, vol. 36, Dec. 2020.

DOI: 10.1016/j.addma.2020.101438

[4] Y. Goueffon, L. Arurault, S. Fontorbes, C. Mabru, C. Tonon, and P. Guigue, "Chemical characteristics, mechanical and thermo-optical properties of black anodic films prepared on 7175 aluminium alloy for space applications," Mater Chem Phys, vol. 120, no. 2–3, p.636–642, Apr. 2010.

DOI: 10.1016/j.matchemphys.2009.12.016

[5] K. Riener, S. Oswald, M. Winkler, and G. J. Leichtfried, "Influence of storage conditions and reconditioning of AlSi10Mg powder on the quality of parts produced by laser powder bed fusion (LPBF)," Addit Manuf, vol. 39, Mar. 2021.

DOI: 10.1016/j.addma.2021.101896

[6] L. Cordova, T. Bor, M. de Smit, S. Carmignato, M. Campos, and T. Tinga, "Effects of powder reuse on the microstructure and mechanical behaviour of Al–Mg–Sc–Zr alloy processed by laser powder bed fusion (LPBF)," Addit Manuf, vol. 36, Dec. 2020.

DOI: 10.1016/j.addma.2020.101625

[7] W. L. Costin, O. Lavigne, and A. Kotousov, "A study on the relationship between microstructure and mechanical properties of acicular ferrite and upper bainite," Materials Science and Engineering A, vol. 663, p.193–203, Apr. 2016.

DOI: 10.1016/j.msea.2016.03.103

[8] C. Colombo, C. A. Biffi, J. Fiocchi, A. Tuissi, and L. M. Vergani, "Effect of optimized heat treatments on the tensile behavior and residual stresses of selective laser melted AlSi10Mg samples," in Key Engineering Materials, 2019, vol. 813 KEM, p.364–369.

DOI: 10.4028/www.scientific.net/KEM.813.364

[9] A. Gloria, R. Montanari, M. Richetta, and A. Varone, "Alloys for aeronautic applications: State of the art and perspectives," Metals (Basel), vol. 9, no. 6, Jun. 2019.

DOI: 10.3390/met9060662