scholarly journals Influence of Adding Modifying Elements and Homogenization Annealing on Laser Melting Process of the Modified AlZnMgCu with 4%Si Alloys

Materials ◽  
2021 ◽  
Vol 14 (20) ◽  
pp. 6154
Author(s):  
Ahmed O. Mosleh ◽  
Asmaa M. Khalil ◽  
Irina S. Loginova ◽  
Alexey N. Solonin
Keyword(s):  
Uniform Distribution ◽  
High Strength ◽  
Melting Process ◽  
Laser Melting ◽  
Solidification Temperature ◽  
Melted Zone ◽  
High Laser ◽  
Average Grain Size ◽  
Distribution Of Elements ◽  
Columnar Grains

AlZnMgCu, the high-strength aluminum alloy, is unsuitable for laser melting applications due to its high hot cracking sensitivity and large solidification temperature range. Adapting this alloy for laser melting processing is a high-demand research issue for extending its use. Thus, this paper investigates the effect of adding 4%Si, 4%Si-Sc+Zr, 4%Si-Ti+B, and homogenization annealing on the laser melting process (LMP) of AlZnMgCu alloy. Homogenization annealing at 500 °C for 6.5 h was selected to dissolve most of the low melting temperature phases into the grain matrix and perform stable alloys for the LMP. The pulsed laser melting process (PLM) was performed on the as-casted and the homogenized samples. The microstructures of the as-casted, the homogenized alloys, and after the LMP were evaluated. In addition, the hardness of the base metal (BM) and laser melted zone (LMZ) were measured. The results revealed that the microstructure was enhanced and refined in the as-cast state by adding the modifiers due to the increasing nucleation potency of solidification sites and the formation of primary Al3(Ti, Zr, Sc) phases. The average grain size was decreased by 15.6 times when adding 4%Si + 0.4%Zr + 0.29%Sc, while it decreased by 10.2 times when adding 4%Si + 1%Ti + 0.2%B. The LMZ of the as-casted samples exhibited a non-uniform distribution of the grains and the elements after the LMP. This was attributed to the evaporation of Zn, Mg during the high laser power process besides the non-uniform distribution of elements and phases in samples during casting. After the laser treating of the homogenized samples with 4%Si-Sc + Zr, uniform columnar grains were formed in the direction of the laser. The presence of Ti and B changed the crystallization nature, resulting in the LMZ with very fine and equiaxed grains due to forming many nucleation centers during solidification. The hardness values have positively increased due to Si addition and adding a combination of Ti + B and Sc + Zr. The maximum hardness was 153.9 ± 5 HV achieved in the LMZ of the homogenized samples of 4%Si + 1%Ti + 0.2%B.

Investigation of selective laser melting process for Cu-5Sn alloy on surface roughness, microstructure and mechanical property

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Peng Yang ◽  
Dingyong He ◽  
Zengjie Wang ◽  
Zhen Tan ◽  
Hanguang Fu ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Mechanical Property ◽  
Surface Roughness ◽  
Selective Laser Melting ◽  
High Strength ◽  
Melting Process ◽  
Scanning Speed ◽  
Laser Melting ◽  
Forming Process ◽  
Content Type

Purpose In this research, the highly dense bulk Cu-5Sn alloy specimens were fabricated using selective laser melting (SLM). This study aims to establish the relationship between laser power (LP), scanning speed (SS) and hatch space (HS) with surface roughness (Ra) and density. To obtain Cu-5Sn alloy formed parts with high strength and low surface roughness. The microstructure and mechanical properties of SLMed Cu-5Sn were investigated. Design/methodology/approach The relative density (RD) was optimized using the response surface method (RSM) and analysis of variance. First, the Ra of SLMed formed specimens was studied to optimize the forming process parameters with a good surface. Then, the dense specimens were studied by ANOVA and the RSM to obtain dense specimens for mechanical property analysis. Findings Dense specimens were obtained by RSM and ANOVA. The tensile properties were compared with the casted specimens. The yield and ultimate strengths increased from 71 and 131 MPa for the cast specimens to 334 and 489 MPa for the SLMed specimens, respectively. The ductility increased significantly from 11% to 23%, due to the refined microstructure of the SLMed specimens, as well as the formation of many twin crystals. Originality/value The Ra, RD and mechanical properties of SLM specimens Cu-5Sn were systematically studied, and the influencing factors were analyzed together. This study provides a theoretical and practical example to improve the surface quality and RD.

scholarly journals The Effect of Selective Laser Melting Process Parameters on the Microstructure and Mechanical Properties of Al6061 and AlSi10Mg Alloys

Materials ◽  
2018 ◽  
Vol 12 (1) ◽  
pp. 12 ◽  
Author(s):  
Ahmed Maamoun ◽  
Yi Xue ◽  
Mohamed Elbestawi ◽  
Stephen Veldhuis
Keyword(s):  
Mechanical Properties ◽  
Selective Laser Melting ◽  
Process Parameters ◽  
High Strength ◽  
Melting Process ◽  
Laser Melting ◽  
Influence Of Process Parameters ◽  
Wide Range ◽  
Powder Characteristics

Additive manufacturing (AM) offers customization of the microstructures and mechanical properties of fabricated components according to the material selected and process parameters applied. Selective laser melting (SLM) is a commonly-used technique for processing high strength aluminum alloys. The selection of SLM process parameters could control the microstructure of parts and their mechanical properties. However, the process parameters limit and defects obtained inside the as-built parts present obstacles to customized part production. This study investigates the influence of SLM process parameters on the quality of as-built Al6061 and AlSi10Mg parts according to the mutual connection between the microstructure characteristics and mechanical properties. The microstructure of both materials was characterized for different parts processed over a wide range of SLM process parameters. The optimized SLM parameters were investigated to eliminate internal microstructure defects. The behavior of the mechanical properties of parts was presented through regression models generated from the design of experiment (DOE) analysis for the results of hardness, ultimate tensile strength, and yield strength. A comparison between the results obtained and those reported in the literature is presented to illustrate the influence of process parameters, build environment, and powder characteristics on the quality of parts produced. The results obtained from this study could help to customize the part’s quality by satisfying their design requirements in addition to reducing as-built defects which, in turn, would reduce the amount of the post-processing needed.

scholarly journals Multi-lattice inner structures for high-strength and light-weight in metal selective laser melting process

2019 ◽  
Vol 175 ◽  
pp. 107786 ◽  
Author(s):  
Dongseok Kang ◽  
Sanghu Park ◽  
Yong Son ◽  
Simo Yeon ◽  
Sang Hoon Kim ◽  
...  
Keyword(s):  
Selective Laser Melting ◽  
High Strength ◽  
Melting Process ◽  
Light Weight ◽  
Laser Melting ◽  
Selective Laser Melting Process

scholarly journals Achieving Ti-5Al-4Sn-2Zr-1Mo-0.25Si-1Nb Alloys with High Strength and Moderate Ductility through Selective Laser Melting

Materials ◽  
2020 ◽  
Vol 13 (23) ◽  
pp. 5527
Author(s):  
Jiangtao Ran ◽  
Xiaojing Sun ◽  
Shiliang Wei ◽  
Zhuo Chen ◽  
Hong Zhao
Keyword(s):  
Tensile Strength ◽  
Titanium Alloy ◽  
Selective Laser Melting ◽  
Laser Power ◽  
High Strength ◽  
Composition Analysis ◽  
Laser Melting ◽  
Energy Dispersion Spectrum ◽  
Average Grain Size ◽  
Cruise Missiles

Ti-5Al-4Sn-2Zr-1Mo-0.25Si-1Nb (TA32) titanium alloy is a kind of near α high temperature titanium alloy with great application prospects in aero-engine afterburners and cruise missiles. However, there are still few studies on the microstructure and mechanical properties of TA32 specimens produced by selective laser melting (SLM) technology. In this study, TA32 specimens with high strength (tensile strength of 1267 MPa) and moderate ductility (elongation after fracture of 8%) were obtained by selective laser melting. The effect of laser power on the microstructure and mechanical behavior was studied and the results demonstrated that the average grain size increases with increasing laser power from 200 W to 400 W. Micro-zone composition analysis was carried out by energy dispersion spectrum (EDS), showing that the Al concentration inner grains is higher than that near grain boundaries. Fracture analysis results demonstrated that the fracture mode of SLM TA32 specimens was cleavage fracture. The tensile strength of the specimens built with a laser power of 250 W at 500 °C, 550 °C and 600 °C was measured as 869 MPa, 819 MPa and 712 MPa, respectively.

scholarly journals Effect of Selective Laser Melting Process Parameters on the Quality of Al Alloy Parts: Powder Characterization, Density, Surface Roughness, and Dimensional Accuracy

Materials ◽  
2018 ◽  
Vol 11 (12) ◽  
pp. 2343 ◽  
Author(s):  
Ahmed Maamoun ◽  
Yi Xue ◽  
Mohamed Elbestawi ◽  
Stephen Veldhuis
Keyword(s):  
Surface Roughness ◽  
Selective Laser Melting ◽  
Process Parameters ◽  
Dimensional Accuracy ◽  
High Strength ◽  
Melting Process ◽  
Al Alloys ◽  
Al Alloy ◽  
Laser Melting

Additive manufacturing (AM) of high-strength Al alloys promises to enhance the performance of critical components related to various aerospace and automotive applications. The key advantage of AM is its ability to generate lightweight, robust, and complex shapes. However, the characteristics of the as-built parts may represent an obstacle to the satisfaction of the parts’ quality requirements. The current study investigates the influence of selective laser melting (SLM) process parameters on the quality of parts fabricated from different Al alloys. A design of experiment (DOE) was used to analyze relative density, porosity, surface roughness, and dimensional accuracy according to the interaction effect between the SLM process parameters. The results show a range of energy densities and SLM process parameters for AlSi10Mg and Al6061 alloys needed to achieve “optimum” values for each performance characteristic. A process map was developed for each material by combining the optimized range of SLM process parameters for each characteristic to ensure good quality of the as-built parts. This study is also aimed at reducing the amount of post-processing needed according to the optimal processing window detected.

scholarly journals Evaluation of the Microstructure and Mechanical Properties of a New Modified Cast and Laser-Melted AA7075 Alloy

Materials ◽  
2019 ◽  
Vol 12 (20) ◽  
pp. 3430 ◽  
Author(s):  
Asmaa M. Khalil ◽  
Irina S. Loginova ◽  
Andrey V. Pozdniakov ◽  
Ahmed O. Mosleh ◽  
Alexey N. Solonin
Keyword(s):  
Mechanical Properties ◽  
Corrosion Resistance ◽  
Melting Process ◽  
Scanning Speed ◽  
Elemental Distribution ◽  
Transition Elements ◽  
Laser Melting ◽  
Melted Zone ◽  
Microstructure And Mechanical Properties ◽  
Standard Alloy

The mechanical properties and microstructure of as-cast and homogenized AA7075 were investigated. This alloy was modified by adding transition elements 0.3%Sc + 0.5%Zr, 1%Ti + 0.2%B, and 1%Fe + 1%Ni for use in additive manufacturing applications. After adding Ti + B and Sc + Zr, the structure became uniform and finer with the formation of the Al3(Sc, Zr) and TiB2 phases. Coarse structures were obtained with the formation of an extremely unfavorable morphology, close to a needle-like structure when Fe + Ni was added. The mechanical properties of the modified alloys were increased compared to those of the standard alloy, where the best ultimate tensile strength (UTS) and yield strength (YS) were obtained in the AA7075-TiB alloy compared to the standard alloy in as-cast and homogenized conditions, and the highest hardness value was provided by Fe + Ni additives. The effect of the laser melting process on the microstructure and mechanical properties was investigated. Single laser melts were performed on these alloys using 330 V and a scanning speed of 8 mm/s. During the laser melting, the liquation of the alloying elements occurred due to non-equilibrium solidification. A change in the microstructures was observed within the melt zone and heat-affected zone (HAZ). The hardness of the laser-melted zone (LMZ) after adding the modification elements was increased in comparison with that of the standard alloy. Corrosion testing was performed using a solution of 100 mL distilled water, 3.1 g NaCl, and 1 mL HCl over 5, 10, and 30 min and 1 and 2 h. The corrosion resistance of the alloy modified with FeNi was low because of the non-uniform elemental distribution along the LMZ, but in the case of modification with ScZr and TiB, the corrosion resistance was better compared to that of the standard alloy.

scholarly journals Defect Prevention in Selective Laser Melting Components: Compositional and Process Effects

Materials ◽  
2019 ◽  
Vol 12 (22) ◽  
pp. 3791 ◽  
Author(s):  
Hossein Eskandari Sabzi ◽  
Pedro E. J. Rivera-Díaz-del-Castillo
Keyword(s):  
Selective Laser Melting ◽  
Thermal Stresses ◽  
Defect Formation ◽  
Austenitic Stainless Steels ◽  
Melting Process ◽  
Physical Analysis ◽  
Laser Melting ◽  
Solidification Temperature ◽  
Process Effects ◽  
Defect Prevention

A model to predict the conditions for printability is presented. The model focuses on crack prevention, as well as on avoiding the formation of defects such as keyholes, balls and lack of fusion. Crack prevention is ensured by controlling the solidification temperature range and path, as well as via quantifying its ability to resist thermal stresses upon solidification. Defect formation prevention is ensured by controlling the melt pool geometry and by taking into consideration the melting properties. The model’s core relies on thermodynamics and physical analysis to ensure optimal printability, and in turn offers key information for alloy design and selective laser melting process control. The model is shown to describe accurately defect formation of 316L austenitic stainless steels reported in the literature.

scholarly journals On the Effect of Selective Laser Melting Process Parameters on the Microstructure and Mechanical Properties of Al Alloys

2018 ◽  
Author(s):  
Ahmed Maamoun ◽  
Yi Xue ◽  
Mohamed Elbestawi ◽  
Stephen Veldhuis
Keyword(s):  
Mechanical Properties ◽  
Selective Laser Melting ◽  
Process Parameters ◽  
High Strength ◽  
Melting Process ◽  
Laser Melting ◽  
Influence Of Process Parameters ◽  
Microstructure And Mechanical Properties ◽  
Wide Range

Additive manufacturing (AM) offers customization of microstructure and mechanical properties of fabricated components according to the material selected, and process parameters applied. Selective laser melting (SLM) is the commonly used technique for processing high strength aluminum alloys. Selection of SLM process parameters could control the microstructure of parts and their mechanical properties. However, the process parameters limit and defects obtained inside the as-built parts present obstacles to customized part production. This study investigates the influence of SLM process parameters on the quality of as-built Al6061 and AlSi10Mg parts according to the mutual connection between the microstructure characteristics and mechanical properties. The microstructure of both materials was characterized for different parts processed over a wide range of SLM process parameters. The optimized SLM parameters were investigated to eliminate the internal microstructure defects. The behaviour of mechanical properties of parts was presented through regression models generated from the design of experiment (DOE) analysis for the results of hardness, ultimate tensile strength, and yield strength. A comparison between the results obtained and that reported in the literature is presented to illustrate the influence of process parameters, build environment, and powder characteristics on the quality of parts produced. The results obtained from this study could help to customize the part’s quality by satisfying their design requirements in addition to reducing the as-built defects which in turn reduce the amount of the post-processing needed.

LESCALLOY 300M VAC ARC

Alloy Digest ◽  
1993 ◽  
Vol 42 (2) ◽  
Keyword(s):  
Fracture Toughness ◽  
Tensile Strength ◽  
High Strength ◽  
Melting Process ◽  
Heat Treating ◽  
Pressure Vessels ◽  
Low Alloy Steel ◽  
Steel Company ◽  
High Hardenability ◽  
Ingot Structure

Abstract LESCALLOY 300M VAC ARC is a low-alloy steel with an excellent combination of high hardenability and high strength coupled with good ductility and good toughness. Its tensile strength ranges from 280,000 to 300,000 psi. It is produced by the vacuum consumable electrode melting process to provide optimum cleanliness and preferred ingot structure. Its applications include aircraft components, pressure vessels and fasteners. This datasheet provides information on composition, physical properties, elasticity, and tensile properties as well as fracture toughness. It also includes information on forming, heat treating, machining, joining, and surface treatment. Filing Code: SA-321. Producer or source: Latrobe Steel Company. Originally published March 1976, revised February 1993.

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