A General Strategy for Enhancing 3D Printability of High Laser Reflectivity Pure Aluminum Powder
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tal-based selective laser melting (SLM) is one of the additive manufacturing processes to produce fully dense metallic components with complex geometry.[1] In general, the laser beam is used as a direct energy source to locally melt alloy powders.[2] A reasonable laser absorptivity of metal powder is therefore a prerequisite to carry out SLM. Given that iron (Fe), titanium (Ti), cobalt (Co), and nickel (Ni) have good laser absorptivity, their alloys are major printable materials in the current market and printed parts are being made by the
KANG GENG and QINGSHAN ZHU is with the State Key Laboratory of Multiphase Complex Systems, Institute of Process Engineering, Chinese Academy of Sciences, No.1 Zhongguancun North 2nd St., Beijing 100190, P.R. China and also with the University of Chinese Academy of Sciences, No.19 (A) Yuquan Road, Beijing 100049, P.R. China. YAFENG YANG is with the State Key Laboratory of Multiphase Complex Systems, Institute of Process Engineering, Chinese Academy of Sciences and also with the University of Chinese Academy of Sciences and also with the Dalian National Laboratory for Clean Energy, Dalian 116023, P.R. China. Contact e-mail: [email protected] SHAOFU LI is with the State Key Laboratory of Multiphase Complex Systems, Institute of Process Engineering, Chinese Academy of Sciences and also with the Dalian National Laboratory for Clean Energy. R.D.K. MISRA is with the Department of Metallurgical, Materials and Biomedical Engineering, University of Texas at El Paso, 500 W. University Avenue, El Paso, TX 79968. Manuscript submitted April 30, 2019.
METALLURGICAL AND MATERIALS TRANSACTIONS A
SLM process.[3] In contrast, high laser reflectivity of aluminum (Al) makes it incompatible with SLM to print components.[4–6] At present, reliably printed Al alloys are mainly limited to Al-Si-based alloys with excellent melt fluidity,[7] which constitute a small fraction of Al alloys. One key issue of the incompatibility of Al alloys with SLM is related to the incomplete melting of local metal powders caused by high laser reflectivity. Currently, the majority of studies on SLM of Al alloys focused on the manufacturing process, including optimization of process parameters, microstructure, and mechanical property evaluation. However, the issue of high laser reflectivity of Al powder has not been addressed. In principle, the possible effective solution to improve the laser absorptivity of Al alloy powders is to introduce additives with high laser absorptivity during powder processing, or to manipulate the surface of the powder from a smooth to a rough surface. The former is based on modifying the material composition to achieve good laser absorptivity. However, to obtain the desired laser absorptivity, a high content of additives are needed. For example, Chang et al.[8] added 20 wt pct SiC particles with high laser absorptivity into AlSi10Mg powders by ball milling of mixed composite powders. Chen et al.[9] used in situ reaction process and gas atomization to synthesize TiB2-reinforced Al-3.8Cu1.3Mg composite p
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