Effect of combined additions of Sc, Zr and Ti on hot-cracking resistance and precipitation behaviour in Al-Mg alloy by L-PBF

Abstract

The request for high-performance aluminum components prompts research into innovative alloys compatible with laser-based additive manufacturing processes, leveraging grain refiners in their composition to mitigate hot-cracking and enhance strength. While the addition of Sc and Zr in Al-Mg alloys has been widely investigated, the high cost and supply risks associated with Sc necessitate reducing its amount and replacing, at least partially, with other inoculants. In this preliminary study, the amount of Sc replaceable with different concentrations of Zr or Ti is evaluated investigating the laser powder bed fusion processability of three powder feedstocks: a pre-alloyed Al-Mg-Zr-Sc powder, a blend of the previous alloy with addition of Zr particles, and a further blend of an alloy depleted of Zr with added Ti particles. The experimental analyses on the laser-processed alloys showed that the standard and the Zr-enriched alloys featured a bimodal microstructure free from cracks with fine equiaxed grains at the edge of the molten pools and coarser grains at their centers. In the alloy variant depleted in Zr with addition of Ti particles a columnar structure was observed and hot-cracks appeared. Thermodynamic simulations of phase formation allowed defining the precipitation kinetics during solidification and direct aging, showing increased precipitation in alloys with higher Zr content, while the presence of Ti resulted in sluggish precipitation. Experimental aging tests demonstrated significant increases in microhardness, with peak values of the modified alloys achieved after 12 h at 375 °C.