The majority of aluminum alloys used for laser powder bed fusion are based on the aluminum–silicon system, particularly alloys containing 7 to 12 wt.% silicon and less than 1 wt.% magnesium. Silicon has a beneficial influence on melt viscosity during casting and laser additive manufacturing and prevents the formation of cracks. This study focused on the development of a new AlSi3.5Mg2.5 alloy for laser powder bed fusion with a Mg-Si content above 1.85 wt.% Mg2Si, which is the solubility limit of the α-aluminum matrix, and a subsequent heat treatment to adjust the mechanical properties with a wide range of strength and ductility values. The characterization of the microstructure was conducted by optical microscopy, scanning electron microscopy, transmission electron microscopy, and differential scanning calorimetry. The mechanical properties were determined by tensile tests and additional tight radius bending tests. The newly developed alloy was compared with AlSi10Mg and Scalmalloy®. AlSi3.5Mg2.5 offers higher strength and ductility than AlSi10Mg, at comparable material costs. The mechanical properties can be adjusted in a wide range of values using a single step heat treatment. After direct ageing, the samples exhibited a ultimate tensile strength (UTS) of 484 ± 1 MPa and an elongation at break of 10.5% ± 1.3%, while after soft annealing, they exhibited a UTS of 179 ± 2 MPa and an elongation at break of 25.6% ± 0.9%.
Leveraging Solute Segregation in Laser Powder Bed Fusion to Achieve Superior Strength and Ductility Via Single-Step Heat Treatment in Ti-Free Grade 300 Maraging Steel
