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Abstract <p>Additive manufacturing (AM) offers a route for producing intricate metal parts; however, fabricating high-strength Al7075 using laser-directed energy deposition poses challenges due to its high reflectivity and crack susceptibility. This study investigates the influence of nano-zirconium (Zr) (0–1.5 wt%) on Al7075 powder characteristics. Uniform dispersion was achieved <i>via</i> tumbler blending. Characterization using XRD and differential scanning calorimetry revealed enhanced thermal stability at 1 wt% Zr, while 1.5 wt% led to a lower melting point, likely due to particle agglomeration. The findings emphasize the importance of tailoring powder composition to optimize processing behavior for metal AM applications.</p> Graphical abstract <p></p>

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Thermal and morphological properties of Zr-modified Al7075 powders for metal additive manufacturing

  • 期刊论文

  • 发表日期：

    2025年11月3日

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  • Sai Kumar Balla,
  • M. Manjaiah,
  • N. Selvaraj,
  • Clodualdo Aranas Jr.

摘要

Abstract

Additive manufacturing (AM) offers a route for producing intricate metal parts; however, fabricating high-strength Al7075 using laser-directed energy deposition poses challenges due to its high reflectivity and crack susceptibility. This study investigates the influence of nano-zirconium (Zr) (0–1.5 wt%) on Al7075 powder characteristics. Uniform dispersion was achieved via tumbler blending. Characterization using XRD and differential scanning calorimetry revealed enhanced thermal stability at 1 wt% Zr, while 1.5 wt% led to a lower melting point, likely due to particle agglomeration. The findings emphasize the importance of tailoring powder composition to optimize processing behavior for metal AM applications.

Graphical abstract