Additive manufacturingAdditive manufacturing (AM) has been rapidly expanding in its capability. A limiting factor in the application of AM methods, such as laser powder-bed fusion (L-PBF), is a deficit in available materials, which is particularly pronounced in a lack of qualified aluminum alloysAluminum alloy. While the presence of scandiumScandium in aluminum alloysAluminum alloy for AM is not new, the concentrations are typically held near a full weight percent to achieve the desired grain refiningGrain refining effect. In lesser quantities, scandiumScandium additions alone are not sufficient to generate crack-free layers, largely a result of supersaturation in the aluminumAluminum matrix, suspending the generation of the Al3Sc dispersoidsDispersoids responsible for enhanced grain refinement. In this work, a trio of novel alloys were synthesized via powder blendingPowder blending to address the presence of cracking through the incorporation of commercially available zirconium dihydride powder. The results show that scandiumScandium amounts can be substantially reduced while still producing significant material strengthStrength.

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Crack Mitigation in Aluminum-Scandium Alloys for Laser Powder-Bed Fusion

  • Nathan Andrew Smith,
  • Mostafa Yakout,
  • Mohamed Elbestawi,
  • Luc Duchesne

摘要

Additive manufacturingAdditive manufacturing (AM) has been rapidly expanding in its capability. A limiting factor in the application of AM methods, such as laser powder-bed fusion (L-PBF), is a deficit in available materials, which is particularly pronounced in a lack of qualified aluminum alloysAluminum alloy. While the presence of scandiumScandium in aluminum alloysAluminum alloy for AM is not new, the concentrations are typically held near a full weight percent to achieve the desired grain refiningGrain refining effect. In lesser quantities, scandiumScandium additions alone are not sufficient to generate crack-free layers, largely a result of supersaturation in the aluminumAluminum matrix, suspending the generation of the Al3Sc dispersoidsDispersoids responsible for enhanced grain refinement. In this work, a trio of novel alloys were synthesized via powder blendingPowder blending to address the presence of cracking through the incorporation of commercially available zirconium dihydride powder. The results show that scandiumScandium amounts can be substantially reduced while still producing significant material strengthStrength.