Effective Platform Heating for Laser Powder Bed Fusion of an Al-Mn-Sc-Based Alloy.

Platform heating is one of the effective strategies used in laser powder bed fusion (LPBF) to avoid cracking during manufacturing, especially when building relatively large-size components, as it removes significant process-induced residual strains. In this work, we propose a novel and simple method to spare the elaborate post-processing heat treatment typically needed for LPBF Al-Sc alloys without compromising the mechanical properties. We systematically investigated the effects of LPBF platform heating at 200 °C on the residual stress relief, microstructure, and mechanical performance of a high-strength Al-Mn-Sc alloy. The results reveal that LPBF platform heating at 200 °C is sufficient to largely relieve the process-induced residual stresses compared to parts built on an unheated 35 °C platform. Meanwhile, the platform heating triggered the dynamic precipitation of uniformly dispersed (1.5-2 nm) Sc-rich nano-clusters. Their formation in a high number density (1.75 × 1024 m-3) resulted in a ~20% improvement in tensile yield strength (522 MPa) compared to the build on the unheated platform, without sacrificing the ductility (up to 18%). The improved mechanical properties imply that platform heating at 200 °C can strengthen the LPBF-synthesised Sc-containing Al alloys via in situ aging, which is further justified by an in situ measurement study revealing that the developing temperatures in the LPBF part are within the aging temperature range of Al-Sc alloys. Without any post-LPBF treatments, these mechanical properties have proven better than those of most Al-Sc alloys through long-time post-LPBF heat treatment.

Ultrastrong nanotwinned titanium alloys through additive manufacturing.

Titanium alloys, widely used in the aerospace, automotive and energy sectors, require complex casting and thermomechanical processing to achieve the high strengths required for load-bearing applications. Here we reveal that additive manufacturing can exploit thermal cycling and rapid solidification to create ultrastrong and thermally stable titanium alloys, which may be directly implemented in service. As demonstrated in a commercial titanium alloy, after simple post-heat treatment, adequate elongation and tensile strengths over 1,600 MPa are achieved. The excellent properties are attributed to the unusual formation of dense, stable and internally twinned nanoprecipitates, which are rarely observed in traditionally processed titanium alloys. These nanotwinned precipitates are shown to originate from a high density of dislocations with a dominant screw character and formed from the additive manufacturing process. The work here paves the way to fabricate structural materials with unique microstructures and excellent properties for broad applications.

Training high-strength aluminum alloys to withstand fatigue.

The fatigue performance of high strength aluminum alloys used in planes, trains, trucks and automobiles is notoriously poor. Engineers must design around this important limitation to use Al alloys for light-weighting of transportation structures. An alternative concept for microstructure design for improved fatigue strength is demonstrated in this work. Microstructures are designed to exploit the mechanical energy imparted during the initial cycles of fatigue to dynamically heal the inherent weak points in the microstructure. The fatigue life of the highest strength Aluminum alloys is improved by 25x, and the fatigue strength is raised to ~1/2 the tensile strength. The approach embraces the difference between static and dynamic loading and represents a conceptual change in microstructural design for fatigue.

Precipitation strengthening of aluminum alloys by room-temperature cyclic plasticity.

High-strength aluminum alloys are important for lightweighting vehicles and are extensively used in aircraft and, increasingly, in automobiles. The highest-strength aluminum alloys require a series of high-temperature "bakes" (120° to 200°C) to form a high number density of nanoparticles by solid-state precipitation. We found that a controlled, room-temperature cyclic deformation is sufficient to continuously inject vacancies into the material and to mediate the dynamic precipitation of a very fine (1- to 2-nanometer) distribution of solute clusters. This results in better material strength and elongation properties relative to traditional thermal treatments, despite a much shorter processing time. The microstructures formed are much more uniform than those characteristic of traditional thermal treatments and do not exhibit precipitate-free zones. These alloys are therefore likely to be more resistant to damage.

(Al,Mg)3La: a new phase in the Mg-Al-La system.

During an investigation of the Mg-rich end of the Mg-Al-La system, a new ternary phase with the composition of (Al,Mg)3La was identified. The crystal structure of this phase was determined by conventional X-ray powder diffraction and transmission electron microscopy analysis and refined using high-resolution X-ray powder diffraction. The (Al,Mg)3La phase is found to have an orthorhombic structure with a space group of C2221 and lattice parameters of a = 4.3365 (1) Å, b = 18.8674 (4) Šand c = 4.4242 (1) Å, which is distinctly different from the binary Al3La phase (P63/mmc). The resolved structure of the (Al,Mg)3La phase is further verified by high-angle annular dark-field scanning transmission electron microscopy.