Enhanced mechanical performance via laser induced nanostructure formation in an additively manufactured lightweight aluminum alloy

Aiden A. Martin; Joshua A. Hammons; Hunter B. Henderson; Nicholas P. Calta; Michael H. Nielsen; Caitlyn C. Cook; Jianchao Ye; Alyssa A. Maich; Nicholas E. Teslich; Tian T. Li; Michael J. Thompson; Matthew F. Besser; Manyalibo J. Matthews; Ryan T. Ott; Orlando Rios; Scott K. McCall; Trevor M. Willey; Jonathan R.I. Lee

doi:10.1016/j.apmt.2021.100972

Enhanced mechanical performance via laser induced nanostructure formation in an additively manufactured lightweight aluminum alloy

Aiden A. Martin, Joshua A. Hammons, Hunter B. Henderson, Nicholas P. Calta, Michael H. Nielsen, Caitlyn C. Cook, Jianchao Ye, Alyssa A. Maich, Nicholas E. Teslich, Tian T. Li, Michael J. Thompson, Matthew F. Besser, Manyalibo J. Matthews, Ryan T. Ott, Orlando Rios, Scott K. McCall, Trevor M. Willey, Jonathan R.I. Lee

Research output: Contribution to journal › Article › peer-review

21 Scopus citations

Abstract

To date, the primary focus of metal additive manufacturing (AM) research has been the development of strategies for fabricating complex architectures, reducing internal stress and optimizing microstructure. Traditional Al alloys have presented further challenges in this effort due to solidification cracking and complex laser coupling dynamics. To overcome these limitations, identification of novel alloys that exploit the rapid solidification conditions inherent in laser-based AM is required. In this work, laser-induced melting of an Al-8Ce-10Mg alloy is revealed to generate a nanoscale microstructure which results in improved hardness, tensile strength, and mitigated solidification cracking (e.g., hot tearing) in single laser tracks in as-cast material and laser powder bed fusion (LPBF)-fabricated components. In situ X-ray imaging shows the nanostructure arises from laser-induced melting of intermetallic particles embedded into the alloy during casting and then rapid resolidification of the molten material in ~ 400 µs. The formed Ce-rich nanostructures are highly resistant to thermal coarsening at 300 °C, as confirmed by microscopy and retention of tensile properties. These results pave the way for development of AM-specific Al alloys that possess the ability to form mechanically favorable nanostructures in fabricated components due to the rapid cooling inherent in LPBF.

Original language	English
Article number	100972
Journal	Applied Materials Today
Volume	22
DOIs	https://doi.org/10.1016/j.apmt.2021.100972
State	Published - Mar 2021
Externally published	Yes

Funding

This work was performed under the auspices of the U.S. Department of Energy (DOE) by Lawrence Livermore National Laboratory (LLNL) under Contract No. DE-AC52–07NA27344. Project 17-ERD-042 was funded by the Laboratory Directed Research and Development (LDRD) Program at LLNL. Portions of this research was sponsored by the Critical Materials Institute, an Energy Innovation Hub funded by U.S. DOE, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office. This research used resources of the Advanced Photon Source, a U.S. DOE Office of Science User Facility operated for the DOE Office of Science by Argonne National Laboratory under Contract No. DE-AC02–06CH11357. The authors gratefully acknowledge sample preparation and analysis by E. Sedillo, D. L. Rosas and S. Torres (LLNL), and Z. C. Sims (UTK), the support of K. Fezzaa and A. Deriy (Beamline 32-ID, APS) and J. Ilavsky (Beamline 9-ID, APS). Material specimens for tensile testing were prepared by J. Schaefer at The University of Dayton Research Institute with support through the Air Force Life Cycle Management Center Research Laboratory and the Metals Technology Office (AFLCMC/EXPT/MTO) - Contract GS05Q17BMD0005. This work was performed under the auspices of the U.S. Department of Energy (DOE) by Lawrence Livermore National Laboratory (LLNL) under Contract No. DE-AC52?07NA27344. Project 17-ERD-042 was funded by the Laboratory Directed Research and Development (LDRD) Program at LLNL. Portions of this research was sponsored by the Critical Materials Institute, an Energy Innovation Hub funded by U.S. DOE, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office. This research used resources of the Advanced Photon Source, a U.S. DOE Office of Science User Facility operated for the DOE Office of Science by Argonne National Laboratory under Contract No. DE-AC02?06CH11357. The authors gratefully acknowledge sample preparation and analysis by E. Sedillo, D. L. Rosas and S. Torres (LLNL), and Z. C. Sims (UTK), the support of K. Fezzaa and A. Deriy (Beamline 32-ID, APS) and J. Ilavsky (Beamline 9-ID, APS). Material specimens for tensile testing were prepared by J. Schaefer at The University of Dayton Research Institute with support through the Air Force Life Cycle Management Center Research Laboratory and the Metals Technology Office (AFLCMC/EXPT/MTO) - Contract GS05Q17BMD0005.

Funders	Funder number
AFLCMC
Air Force Life Cycle Management Center Research Laboratory
Critical Materials Institute
EXPT
MTO	GS05Q17BMD0005
Metals Technology Office
U.S. Department of Energy
Advanced Manufacturing Office
Office of Science
Office of Energy Efficiency and Renewable Energy
Argonne National Laboratory	DE-AC02–06CH11357
Lawrence Livermore National Laboratory	17-ERD-042, DE-AC52–07NA27344
Laboratory Directed Research and Development
University of Dayton

Keywords

Additive manufacturing
Aluminum alloy
High strength
Laser powder bed fusion
Nanostructure

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1016/j.apmt.2021.100972

Cite this

Martin, A. A., Hammons, J. A., Henderson, H. B., Calta, N. P., Nielsen, M. H., Cook, C. C., Ye, J., Maich, A. A., Teslich, N. E., Li, T. T., Thompson, M. J., Besser, M. F., Matthews, M. J., Ott, R. T., Rios, O., McCall, S. K., Willey, T. M., & Lee, J. R. I. (2021). Enhanced mechanical performance via laser induced nanostructure formation in an additively manufactured lightweight aluminum alloy. Applied Materials Today, 22, Article 100972. https://doi.org/10.1016/j.apmt.2021.100972

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title = "Enhanced mechanical performance via laser induced nanostructure formation in an additively manufactured lightweight aluminum alloy",

abstract = "To date, the primary focus of metal additive manufacturing (AM) research has been the development of strategies for fabricating complex architectures, reducing internal stress and optimizing microstructure. Traditional Al alloys have presented further challenges in this effort due to solidification cracking and complex laser coupling dynamics. To overcome these limitations, identification of novel alloys that exploit the rapid solidification conditions inherent in laser-based AM is required. In this work, laser-induced melting of an Al-8Ce-10Mg alloy is revealed to generate a nanoscale microstructure which results in improved hardness, tensile strength, and mitigated solidification cracking (e.g., hot tearing) in single laser tracks in as-cast material and laser powder bed fusion (LPBF)-fabricated components. In situ X-ray imaging shows the nanostructure arises from laser-induced melting of intermetallic particles embedded into the alloy during casting and then rapid resolidification of the molten material in ~ 400 µs. The formed Ce-rich nanostructures are highly resistant to thermal coarsening at 300 °C, as confirmed by microscopy and retention of tensile properties. These results pave the way for development of AM-specific Al alloys that possess the ability to form mechanically favorable nanostructures in fabricated components due to the rapid cooling inherent in LPBF.",

keywords = "Additive manufacturing, Aluminum alloy, High strength, Laser powder bed fusion, Nanostructure",

author = "Martin, {Aiden A.} and Hammons, {Joshua A.} and Henderson, {Hunter B.} and Calta, {Nicholas P.} and Nielsen, {Michael H.} and Cook, {Caitlyn C.} and Jianchao Ye and Maich, {Alyssa A.} and Teslich, {Nicholas E.} and Li, {Tian T.} and Thompson, {Michael J.} and Besser, {Matthew F.} and Matthews, {Manyalibo J.} and Ott, {Ryan T.} and Orlando Rios and McCall, {Scott K.} and Willey, {Trevor M.} and Lee, {Jonathan R.I.}",

note = "Publisher Copyright: {\textcopyright} 2021 Elsevier Ltd",

year = "2021",

month = mar,

doi = "10.1016/j.apmt.2021.100972",

language = "English",

volume = "22",

journal = "Applied Materials Today",

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Martin, AA, Hammons, JA, Henderson, HB, Calta, NP, Nielsen, MH, Cook, CC, Ye, J, Maich, AA, Teslich, NE, Li, TT, Thompson, MJ, Besser, MF, Matthews, MJ, Ott, RT, Rios, O, McCall, SK, Willey, TM & Lee, JRI 2021, 'Enhanced mechanical performance via laser induced nanostructure formation in an additively manufactured lightweight aluminum alloy', Applied Materials Today, vol. 22, 100972. https://doi.org/10.1016/j.apmt.2021.100972

TY - JOUR

T1 - Enhanced mechanical performance via laser induced nanostructure formation in an additively manufactured lightweight aluminum alloy

AU - Martin, Aiden A.

AU - Hammons, Joshua A.

AU - Henderson, Hunter B.

AU - Calta, Nicholas P.

AU - Nielsen, Michael H.

AU - Cook, Caitlyn C.

AU - Ye, Jianchao

AU - Maich, Alyssa A.

AU - Teslich, Nicholas E.

AU - Li, Tian T.

AU - Thompson, Michael J.

AU - Besser, Matthew F.

AU - Matthews, Manyalibo J.

AU - Ott, Ryan T.

AU - Rios, Orlando

AU - McCall, Scott K.

AU - Willey, Trevor M.

AU - Lee, Jonathan R.I.

PY - 2021/3

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N2 - To date, the primary focus of metal additive manufacturing (AM) research has been the development of strategies for fabricating complex architectures, reducing internal stress and optimizing microstructure. Traditional Al alloys have presented further challenges in this effort due to solidification cracking and complex laser coupling dynamics. To overcome these limitations, identification of novel alloys that exploit the rapid solidification conditions inherent in laser-based AM is required. In this work, laser-induced melting of an Al-8Ce-10Mg alloy is revealed to generate a nanoscale microstructure which results in improved hardness, tensile strength, and mitigated solidification cracking (e.g., hot tearing) in single laser tracks in as-cast material and laser powder bed fusion (LPBF)-fabricated components. In situ X-ray imaging shows the nanostructure arises from laser-induced melting of intermetallic particles embedded into the alloy during casting and then rapid resolidification of the molten material in ~ 400 µs. The formed Ce-rich nanostructures are highly resistant to thermal coarsening at 300 °C, as confirmed by microscopy and retention of tensile properties. These results pave the way for development of AM-specific Al alloys that possess the ability to form mechanically favorable nanostructures in fabricated components due to the rapid cooling inherent in LPBF.

AB - To date, the primary focus of metal additive manufacturing (AM) research has been the development of strategies for fabricating complex architectures, reducing internal stress and optimizing microstructure. Traditional Al alloys have presented further challenges in this effort due to solidification cracking and complex laser coupling dynamics. To overcome these limitations, identification of novel alloys that exploit the rapid solidification conditions inherent in laser-based AM is required. In this work, laser-induced melting of an Al-8Ce-10Mg alloy is revealed to generate a nanoscale microstructure which results in improved hardness, tensile strength, and mitigated solidification cracking (e.g., hot tearing) in single laser tracks in as-cast material and laser powder bed fusion (LPBF)-fabricated components. In situ X-ray imaging shows the nanostructure arises from laser-induced melting of intermetallic particles embedded into the alloy during casting and then rapid resolidification of the molten material in ~ 400 µs. The formed Ce-rich nanostructures are highly resistant to thermal coarsening at 300 °C, as confirmed by microscopy and retention of tensile properties. These results pave the way for development of AM-specific Al alloys that possess the ability to form mechanically favorable nanostructures in fabricated components due to the rapid cooling inherent in LPBF.

KW - Additive manufacturing

KW - Aluminum alloy

KW - High strength

KW - Laser powder bed fusion

KW - Nanostructure

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DO - 10.1016/j.apmt.2021.100972

M3 - Article

AN - SCOPUS:85101059613

SN - 2352-9407

VL - 22

JO - Applied Materials Today

JF - Applied Materials Today

M1 - 100972

ER -

Enhanced mechanical performance via laser induced nanostructure formation in an additively manufactured lightweight aluminum alloy

Abstract

Funding

Keywords

UN SDGs

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