Evaluation of Microstructure and Hardness of Novel Al-Fe-Ni Alloys with High Thermal Stability for Laser Additive Manufa
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https://doi.org/10.1007/s11837-020-04321-2 Ó 2020 The Minerals, Metals & Materials Society
ALUMINUM AND MAGNESIUM: CASTING TECHNOLOGY AND SOLIDIFICATION
Evaluation of Microstructure and Hardness of Novel Al-Fe-Ni Alloys with High Thermal Stability for Laser Additive Manufacturing I.S. LOGINOVA ,1,2,4 M.V. SAZERAT,2,3 P.A. LOGINOV,2 A.V. POZDNIAKOV,2 N.A. POPOV,1 and A.N. SOLONIN2 1.—Ural Federal University, 19, Mira Street, Ekaterinburg, Russian Federation 620002. 2.—National University of Science and Technology ‘‘MISiS’’, 4, Leninsky Ave, Moscow, Russian Federation 119991. 3.—IMT Mines Albi, Alle´e des sciences, Albi 81000, France. 4.—e-mail: [email protected]
The microstructure and phase composition of cast and laser-melted Al-Fe-Ni alloys were investigated. Two main phases—Al3(Ni,Fe) and Al9FeNi—were formed in the as-cast state. A fine microstructure without porosity or solidification cracks was observed in the Al-Fe-Ni alloys after laser treatment. The hardness of the laser-melted alloys was 2.5–3 times higher than the hardness of the as-cast alloys owing to the formation of an aluminum-based solid solution and fine eutectic particles. The formation of the primary Al9FeNi phase was suppressed as a result of the high cooling rate. Annealing these alloys at temperatures less than 300°C demonstrated the high thermal stability of the microstructure while maintaining the hardness. The Al-Fe-Ni alloys investigated in this study are promising heat-resistant materials for additive manufacturing because of their fine, stable structure, and the low interdiffusion coefficients of Fe and Ni.
INTRODUCTION Additive manufacturing (AM) technologies offer the capability to produce parts with improved properties. Selective laser melting (SLM) and direct metal deposition (DMD) are the most common technologies used to manufacture parts from metal powders. In both technologies, parts are formed layer by layer from the powder upon laser beam impact.1–3 Aluminum (Al) alloys, having low density and desirable mechanical and technological properties, are good candidates for AM. The list of Al alloys suitable for AM is increasing every year and currently includes powders in the following forms: Al-Si (AlSi12,4 AlSi10Mg,5 AlSi7Mg 6 ), Al-Mg-Sc (Al-6.2Mg-0.36Sc-0.09Zr,7 Al-4.6Mg0.66Sc-0.42Zr-0.49Mn 8), Al-Zn-Mg (AA7075,9 AA705010), and Al-Cu-Mg (Al-3.5Cu-1.5Mg-1Si11). However, only AlSi10Mg alloy and Al-4.6Mg0.66Sc-0.42Zr-0.49Mn alloy (Scalmalloy) powders are currently being used in commercial applications. The latter material is conducive to the laser melting process because of its narrow effective
solidification range and the presence of a sufficiently large amount of aluminum–silicon eutectic in the structure, as well as the high content of zirconium and scandium. The AlSi10Mg alloy has substantially lower strength than the Scalmalloy but is significantly less expensive. The Al-Cu and Al-Cu-Mg alloys exhibit relatively high strength at both room and elevated temperatures.12 However, the drawback of using these alloys in AM lies in
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