On the experimentation of the laser-powder bed fusion process for high-strength aluminum alloys

On the experimentation of the laser-powder bed fusion process for high-strength aluminum alloys

EL HASSANIN Andrea, PERNA Alessia Serena, SICIGNANO Nicola, BORRELLI Domenico Borrelli, CARAVIELLO Antonio, ASTARITA Antonello

download PDF

Abstract. Additive Manufacturing (AM), a cutting-edge technique developed for the manufacture of prototypes that aims to produce large-scale products tailored for numerous industrial applications, has found increasing space in recent years. In this context, Laser-Powder Bed Fusion (L-PBF) technology represents one of the most intriguing ones considering the large number of processable and under-development alloys. By combining the inherent benefits of this technology, it is then possible to produce components with improved mechanical characteristics and low weight. Nevertheless, improved properties such as thermal and electrical conductivity, strength, and corrosion resistance can be achieved. In this scenario, high-performance aluminum-based alloys, tailored for the metal AM have raised increasing interest in the industrial framework. In this work, the LPBF processing of an Al-Mg-Sc-Zr was investigated. The tensile characteristics, the microhardness, the density and the microstructure of L-PBF specimens were analyzed.

Laser-Powder Bed Fusion, Aluminum Alloys, Material Characterization

Published online 4/24/2024, 8 pages
Copyright © 2024 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: EL HASSANIN Andrea, PERNA Alessia Serena, SICIGNANO Nicola, BORRELLI Domenico Borrelli, CARAVIELLO Antonio, ASTARITA Antonello, On the experimentation of the laser-powder bed fusion process for high-strength aluminum alloys, Materials Research Proceedings, Vol. 41, pp 234-241, 2024

DOI: https://doi.org/10.21741/9781644903131-26

The article was published as article 26 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

[1] A. Katz-Demyanetz, V. V. Popov, A. Kovalevsky, D. Safranchik, A. Koptyug, Powder-bed additive manufacturing for aerospace application: Techniques, metallic and metal/ceramic composite materials and trends, Manuf Rev (Les Ulis) 6 (2019) 5. https://doi.org/10.1051/mfreview/2019003
[2] W. Abd-Elaziem, S. Elkatatny, A.-E. Abd-Elaziem, M. Khedr, M.A. Abd El-baky, M.A. Hassan, M. Abu-Okail, M. Mohammed, A. Järvenpää, T. Allam, A. Hamada, On the current research progress of metallic materials fabricated by laser powder bed fusion process: a review, Journal of Materials Research and Technology 20 (2022) 681–707. https://doi.org/10.1016/j.jmrt.2022.07.085
[3] A.G. Colomo, D. Wood, F. Martina, S.W. Williams, A comparison framework to support the selection of the best additive manufacturing process for specific aerospace applications, International Journal of Rapid Manufacturing 9 (2020) 194. https://doi.org/10.1504/IJRAPIDM.2020.107736
[4] I. Tolosa, F. Garciandía, F. Zubiri, F. Zapirain, A. Esnaola, Study of mechanical properties of AISI 316 stainless steel processed by “selective laser melting”, following different manufacturing strategies, The International Journal of Advanced Manufacturing Technology 51 (2010) 639–647. https://doi.org/10.1007/s00170-010-2631-5
[5] J.L. Leirmo, High Strength Aluminium Alloys in Laser-Based Powder Bed Fusion – a Review, Procedia CIRP 104 (2021) 1747–1752. https://doi.org/10.1016/j.procir.2021.11.294
[6] V.B. Vukkum, R.K. Gupta, Review on corrosion performance of laser powder-bed fusion printed 316L stainless steel: Effect of processing parameters, manufacturing defects, post-processing, feedstock, and microstructure, Mater Des 221 (2022) 110874. https://doi.org/10.1016/j.matdes.2022.110874
[7] T.C. Dzogbewu, D.J. de Beer, Additive manufacturing of NiTi shape memory alloy and its industrial applications, Heliyon 10 (2024) e23369. https://doi.org/10.1016/j.heliyon.2023.e23369
[8] P. Rambabu, N. Eswara Prasad, V. V. Kutumbarao, R.J.H. Wanhill, Aluminium Alloys for Aerospace Applications, in: 2017: pp. 29–52. https://doi.org/10.1007/978-981-10-2134-3_2
[9] M. Javaid, A. Haleem, R.P. Singh, R. Suman, S. Rab, Role of additive manufacturing applications towards environmental sustainability, Advanced Industrial and Engineering Polymer Research 4 (2021) 312–322. https://doi.org/10.1016/j.aiepr.2021.07.005
[10] S.R. Narasimharaju, W. Zeng, T.L. See, Z. Zhu, P. Scott, X. Jiang, S. Lou, A comprehensive review on laser powder bed fusion of steels: Processing, microstructure, defects and control methods, mechanical properties, current challenges and future trends, J Manuf Process 75 (2022) 375–414. https://doi.org/10.1016/j.jmapro.2021.12.033
[11] K.L. Kendig, D.B. Miracle, Strengthening mechanisms of an Al-Mg-Sc-Zr alloy, Acta Mater 50 (2002) 4165–4175. https://doi.org/10.1016/S1359-6454(02)00258-6
[12] Information on https://www.metals4printing.com/home-en/, (n.d.).
[13] A. El Hassanin, A.T. Silvestri, F. Napolitano, D. Borrelli, A. Caraviello, A. Astarita, Investigation of the laser-related parameters in Laser-Powder Bed Fusion of Inconel 718-Cu blends at fixed Volumetric Energy Density, J Manuf Process 99 (2023) 456–468. https://doi.org/10.1016/j.jmapro.2023.05.068
[14] A. El Hassanin, A.T. Silvestri, F. Napolitano, F. Scherillo, A. Caraviello, D. Borrelli, A. Astarita, Laser-powder bed fusion of pre-mixed Inconel718-Cu powders: An experimental study, J Manuf Process 71 (2021) 329–344. https://doi.org/10.1016/j.jmapro.2021.09.028
[15] Kay Geels, Metallographic and Materialographic Specimen Preparation, Light Microscopy, Image Analysis, and Hardness Testing, n.d. https://books.google.it/books?id=oaehZy3Vo1kC
[16] A. du Plessis, Effects of process parameters on porosity in laser powder bed fusion revealed by X-ray tomography, Addit Manuf 30 (2019) 100871. https://doi.org/10.1016/j.addma.2019.100871
[17] T. Ingrassia, V. Nigrelli, V. Ricotta, C. Tartamella, Process parameters influence in additive manufacturing, in: 2017: pp. 261–270. https://doi.org/10.1007/978-3-319-45781-9_27
[18] W. Wang, J. Ning, S.Y. Liang, Prediction of lack-of-fusion porosity in laser powder-bed fusion considering boundary conditions and sensitivity to laser power absorption, The International Journal of Advanced Manufacturing Technology 112 (2021) 61–70. https://doi.org/10.1007/s00170-020-06224-7