Eutectic, precipitation-strengthened alloy via laser fusion of blends of Al-7Ce-10Mg (wt.%), Zr, and Sc powders

Clement N. Ekaputra; David Weiss; Jon Erik Mogonye; David C. Dunand

doi:10.1016/j.actamat.2023.118676

Eutectic, precipitation-strengthened alloy via laser fusion of blends of Al-7Ce-10Mg (wt.%), Zr, and Sc powders

Clement N. Ekaputra, David Weiss, Jon Erik Mogonye, David C. Dunand

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

17 Scopus citations

Abstract

Laser powder-bed fusion was used to create an Al-7Ce-10Mg-0.71Zr-0.23Sc (wt.%) alloy, using hypoeutectic Al-7Ce-10Mg (wt.%) pre-alloyed powder blended with either elemental Zr and Sc powders (∼20 µm in size), or pre-alloyed, concentrated Al-10Zr and Al-10Sc (wt.%) powders (comprised of 1-5 µm Al₃Zr or Al₃Sc particles embedded in a <45 μm Al-rich matrix). The effects of process parameters and powder selection on the homogeneity of the as-fabricated microstructure were investigated via metallography and compared to predictions from a simple numerical model describing the dissolution of Zr powders in the melt pool during printing. Both experiments and model show that decreasing scan speed leads to greater dissolution of Zr and Sc, but remelting has no significant effect. The samples produced with Al-10Zr and Al-10Sc powder additions show greater amounts of Zr and Sc dissolution than those produced with elemental Zr and Sc additions, because of the smaller size (5 µm for prealloyed vs. 20 µm for elemental) and lower melting point (1580 and 1320°C for Al₃Zr, Al₃Sc vs. 1850 and 1541°C for Zr, Sc) of the dissolving species. The alloys fabricated with prealloyed powders display larger amounts of very fine grains (1-2 µm) nucleated by primary L1₂ Al₃(Zr,Sc) precipitates, and a clear hardening response during aging, consistent with supersaturated Zr and Sc forming a high number density of secondary L1₂ Al₃(Zr,Sc) nanoprecipitates.

Original language	English
Article number	118676
Journal	Acta Materialia
Volume	246
DOIs	https://doi.org/10.1016/j.actamat.2023.118676
State	Published - Mar 1 2023
Externally published	Yes

Funding

This work made use of the Materials Characterization and Imaging, which has received support from the MRSEC program (NSF DMR- 1720139 ) of the Materials Research Center at Northwestern University . This work made use of the EPIC facility of the NUANCE Center , which has received support from the MRSEC program (NSF DMR- 1720139 ) at the Materials Research Center , SHyNE Resource (NSF ECCS- 2025633 ), the International Institute for Nanotechnology , IIN (NIH- 210OD026871 ), and the State of Illinois (through the INN). Arc-melting was performed at the Northwestern University Center for Atom-Probe Tomography (NUCAPT) . NUCAPT received support from the MRSEC program (NSF DMR- 1720139 ) at the Materials Research Center, the SHyNE Resource (NSF ECCS- 1542205 ), and the Initiative for Sustainability and Energy (ISEN) at NU . The authors thank Jennifer Glerum, Dr. Jovid Rakhmonov, Prof. Gregory Wagner, Prof. Peter Voorhees ( Northwestern University ), and Anthony Roberts (ARL) for helpful discussions. CNE was supported by the DEVCOM Army Research Laboratory (ARL) Research Associateship Program (RAP) . Research was sponsored by the Army Research Laboratory and was accomplished under Cooperative Agreement Numbers W911NF-20-2-0292 , W911NF-21-2-02199 . The views and conclusions contained in this document are those of the authors and should not be interpreted as representing the official policies, either expressed or implied, of the Army Research Laboratory of the U.S. Government. The U.S. Government is authorized to reproduce and distribute reprints for Government purposes notwithstanding any copyright notation herein. The authors thank Jennifer Glerum, Dr. Jovid Rakhmonov, Prof. Gregory Wagner, Prof. Peter Voorhees (Northwestern University), and Anthony Roberts (ARL) for helpful discussions. CNE was supported by the DEVCOM Army Research Laboratory (ARL) Research Associateship Program (RAP). Research was sponsored by the Army Research Laboratory and was accomplished under Cooperative Agreement Numbers W911NF-20-2-0292, W911NF-21-2-02199. The views and conclusions contained in this document are those of the authors and should not be interpreted as representing the official policies, either expressed or implied, of the Army Research Laboratory of the U.S. Government. The U.S. Government is authorized to reproduce and distribute reprints for Government purposes notwithstanding any copyright notation herein. This work made use of the Materials Characterization and Imaging, which has received support from the MRSEC program (NSF DMR-1720139) of the Materials Research Center at Northwestern University. This work made use of the EPIC facility of the NUANCE Center, which has received support from the MRSEC program (NSF DMR-1720139) at the Materials Research Center, SHyNE Resource (NSF ECCS-2025633), the International Institute for Nanotechnology, IIN (NIH-210OD026871), and the State of Illinois (through the INN). Arc-melting was performed at the Northwestern University Center for Atom-Probe Tomography (NUCAPT). NUCAPT received support from the MRSEC program (NSF DMR-1720139) at the Materials Research Center, the SHyNE Resource (NSF ECCS-1542205), and the Initiative for Sustainability and Energy (ISEN) at NU.

Keywords

Aluminum alloys
L1
Laser powder-bed fusion (L-PBF)
Modeling
Precipitation strengthening

UN SDGs

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

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10.1016/j.actamat.2023.118676

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title = "Eutectic, precipitation-strengthened alloy via laser fusion of blends of Al-7Ce-10Mg (wt.%), Zr, and Sc powders",

abstract = "Laser powder-bed fusion was used to create an Al-7Ce-10Mg-0.71Zr-0.23Sc (wt.%) alloy, using hypoeutectic Al-7Ce-10Mg (wt.%) pre-alloyed powder blended with either elemental Zr and Sc powders (∼20 µm in size), or pre-alloyed, concentrated Al-10Zr and Al-10Sc (wt.%) powders (comprised of 1-5 µm Al3Zr or Al3Sc particles embedded in a <45 μm Al-rich matrix). The effects of process parameters and powder selection on the homogeneity of the as-fabricated microstructure were investigated via metallography and compared to predictions from a simple numerical model describing the dissolution of Zr powders in the melt pool during printing. Both experiments and model show that decreasing scan speed leads to greater dissolution of Zr and Sc, but remelting has no significant effect. The samples produced with Al-10Zr and Al-10Sc powder additions show greater amounts of Zr and Sc dissolution than those produced with elemental Zr and Sc additions, because of the smaller size (5 µm for prealloyed vs. 20 µm for elemental) and lower melting point (1580 and 1320°C for Al3Zr, Al3Sc vs. 1850 and 1541°C for Zr, Sc) of the dissolving species. The alloys fabricated with prealloyed powders display larger amounts of very fine grains (1-2 µm) nucleated by primary L12 Al3(Zr,Sc) precipitates, and a clear hardening response during aging, consistent with supersaturated Zr and Sc forming a high number density of secondary L12 Al3(Zr,Sc) nanoprecipitates.",

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T1 - Eutectic, precipitation-strengthened alloy via laser fusion of blends of Al-7Ce-10Mg (wt.%), Zr, and Sc powders

AU - Ekaputra, Clement N.

AU - Weiss, David

AU - Mogonye, Jon Erik

AU - Dunand, David C.

PY - 2023/3/1

Y1 - 2023/3/1

N2 - Laser powder-bed fusion was used to create an Al-7Ce-10Mg-0.71Zr-0.23Sc (wt.%) alloy, using hypoeutectic Al-7Ce-10Mg (wt.%) pre-alloyed powder blended with either elemental Zr and Sc powders (∼20 µm in size), or pre-alloyed, concentrated Al-10Zr and Al-10Sc (wt.%) powders (comprised of 1-5 µm Al3Zr or Al3Sc particles embedded in a <45 μm Al-rich matrix). The effects of process parameters and powder selection on the homogeneity of the as-fabricated microstructure were investigated via metallography and compared to predictions from a simple numerical model describing the dissolution of Zr powders in the melt pool during printing. Both experiments and model show that decreasing scan speed leads to greater dissolution of Zr and Sc, but remelting has no significant effect. The samples produced with Al-10Zr and Al-10Sc powder additions show greater amounts of Zr and Sc dissolution than those produced with elemental Zr and Sc additions, because of the smaller size (5 µm for prealloyed vs. 20 µm for elemental) and lower melting point (1580 and 1320°C for Al3Zr, Al3Sc vs. 1850 and 1541°C for Zr, Sc) of the dissolving species. The alloys fabricated with prealloyed powders display larger amounts of very fine grains (1-2 µm) nucleated by primary L12 Al3(Zr,Sc) precipitates, and a clear hardening response during aging, consistent with supersaturated Zr and Sc forming a high number density of secondary L12 Al3(Zr,Sc) nanoprecipitates.

AB - Laser powder-bed fusion was used to create an Al-7Ce-10Mg-0.71Zr-0.23Sc (wt.%) alloy, using hypoeutectic Al-7Ce-10Mg (wt.%) pre-alloyed powder blended with either elemental Zr and Sc powders (∼20 µm in size), or pre-alloyed, concentrated Al-10Zr and Al-10Sc (wt.%) powders (comprised of 1-5 µm Al3Zr or Al3Sc particles embedded in a <45 μm Al-rich matrix). The effects of process parameters and powder selection on the homogeneity of the as-fabricated microstructure were investigated via metallography and compared to predictions from a simple numerical model describing the dissolution of Zr powders in the melt pool during printing. Both experiments and model show that decreasing scan speed leads to greater dissolution of Zr and Sc, but remelting has no significant effect. The samples produced with Al-10Zr and Al-10Sc powder additions show greater amounts of Zr and Sc dissolution than those produced with elemental Zr and Sc additions, because of the smaller size (5 µm for prealloyed vs. 20 µm for elemental) and lower melting point (1580 and 1320°C for Al3Zr, Al3Sc vs. 1850 and 1541°C for Zr, Sc) of the dissolving species. The alloys fabricated with prealloyed powders display larger amounts of very fine grains (1-2 µm) nucleated by primary L12 Al3(Zr,Sc) precipitates, and a clear hardening response during aging, consistent with supersaturated Zr and Sc forming a high number density of secondary L12 Al3(Zr,Sc) nanoprecipitates.

KW - Aluminum alloys

KW - L1

KW - Laser powder-bed fusion (L-PBF)

KW - Modeling

KW - Precipitation strengthening

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DO - 10.1016/j.actamat.2023.118676

M3 - Article

AN - SCOPUS:85146227842

SN - 1359-6454

VL - 246

JO - Acta Materialia

JF - Acta Materialia

M1 - 118676

ER -

Eutectic, precipitation-strengthened alloy via laser fusion of blends of Al-7Ce-10Mg (wt.%), Zr, and Sc powders

Abstract

Funding

Keywords

UN SDGs

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