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Additive manufacturing of an ultrastrong, deformable Al alloy with nanoscale intermetallics

Light-weight, high-strength, aluminum (Al) alloys have widespread industrial applications. However, most commercially available high-strength Al alloys, like AA 7075, are not suitable for additive manufacturing due to their high susceptibility to solidification cracking. In this work, a custom Al al...

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Published in:Nature communications 2024-06, Vol.15 (1), p.5122-12
Main Authors: Shang, Anyu, Stegman, Benjamin, Choy, Kenyi, Niu, Tongjun, Shen, Chao, Shang, Zhongxia, Sheng, Xuanyu, Lopez, Jack, Hoppenrath, Luke, Zhang, Bohua Peter, Wang, Haiyan, Bellon, Pascal, Zhang, Xinghang
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container_title Nature communications
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creator Shang, Anyu
Stegman, Benjamin
Choy, Kenyi
Niu, Tongjun
Shen, Chao
Shang, Zhongxia
Sheng, Xuanyu
Lopez, Jack
Hoppenrath, Luke
Zhang, Bohua Peter
Wang, Haiyan
Bellon, Pascal
Zhang, Xinghang
description Light-weight, high-strength, aluminum (Al) alloys have widespread industrial applications. However, most commercially available high-strength Al alloys, like AA 7075, are not suitable for additive manufacturing due to their high susceptibility to solidification cracking. In this work, a custom Al alloy Al 92 Ti 2 Fe 2 Co 2 Ni 2 is fabricated by selective laser melting. Heterogeneous nanoscale medium-entropy intermetallic lamella form in the as-printed Al alloy. Macroscale compression tests reveal a combination of high strength, over 700 MPa, and prominent plastic deformability. Micropillar compression tests display significant back stress in all regions, and certain regions have flow stresses exceeding 900 MPa. Post-deformation analyses reveal that, in addition to abundant dislocation activities in Al matrix, complex dislocation structures and stacking faults form in monoclinic Al 9 Co 2 type brittle intermetallics. This study shows that proper introduction of heterogeneous microstructures and nanoscale medium entropy intermetallics offer an alternative solution to the design of ultrastrong, deformable Al alloys via additive manufacturing. Commercial high-strength Al alloys often suffer from cracking during additive manufacturing. Here, the authors present an additively manufactured, a strong and plastically deformable Al alloy with heterogeneous nanoscale intermetallics.
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subjects 147/143
639/166/988
639/301/1023/1026
639/301/1023/303
Additive manufacturing
Alloys
Aluminum
Aluminum base alloys
Compression
Compression tests
Compressive strength
Deformability
Deformation analysis
Dislocation
Entropy
Formability
High strength alloys
Humanities and Social Sciences
Industrial applications
Intermetallic compounds
Lamella
Laser beam melting
Manufacturing
multidisciplinary
Science
Science (multidisciplinary)
Solidification
Stacking faults
Yield strength
title Additive manufacturing of an ultrastrong, deformable Al alloy with nanoscale intermetallics
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