Laser Powder Bed Fusion (LPBF) is a cutting-edge method for designing and processing complex metallic components that uses a laser to melt thin layers of powder. While LPBF offers unique advantages, however, only a few alloys can be reliably processed by this methodology and, in particular, the number of different aluminium alloys available for LPBF is still rather limited. This talk will review ongoing research on development of new aluminium alloys with transition metals (Fe, Cr, Si, Ti, etc.) having low diffusion coefficients in the aluminium lattice, which are proposed as heat-resistant alloys which can be processed by L-PBF. Accordingly, the manufacturability of a high-strength AlFeCrX (X=Si, Ti) aluminium alloys by LPBF has been studied. AlFeCrX metal powders have been fabricated via gas atomization and their characteristics such as morphology, composition and intermetallic phases have been evaluated. High density (~99.8%) and crack-free parts have been characterized by cross sectional examination of microstructure by optical and scanning electron microscopy (SEM). The average grain size and orientation is measured by electron backscatter diffraction (EBSD) analysis, while x-ray diffraction (XRD) analysis is employed for identification of the precipitates. Mechanical properties are studied by conducting microhardness measurements and tensile tests at different temperatures.

International Metal Additive Manufacturing Symposium French Technical Center for Mechanical Industries (CETIM)