Effect of precipitation kinetics on microstructure and properties of novel Al-Mn-Cr-Zr based alloys developed for powder bed fusion – laser beam process

Abstract

This study investigates the precipitation kinetics and resulting effect on microstructure and property of a family of novel high strength Al-Mn-Cr-Zr alloys designed for powder bed fusion – laser beam process. The alloys have been shown to be printable without solidification cracking along with high supersaturation of solutes in as-printed state. Upon direct ageing, two families of precipitates namely Al-Mn and Al-Zr are observed. Al-Mn containing precipitates, which are observed in as-printed condition as nanometric precipitates decorating special regions are seen to grow preferentially at grain boundaries, which is followed by growth in bulk of the sample. A possible explanation is suggested to be a higher diffusivity at grain boundaries leading to faster growth while depleting solutes around grain boundary region quickly. The Al-Zr precipitation, which normally follows bulk precipitation is observed to co-precipitate with Al-Mn precipitates. Optimised heat treatments are seen to achieve peak hardness of 143 HV at 623 K for 24 h and 142 HV at 648 K for 14 h as compared to 102 HV in as-printed condition for one of the alloys. This overall hardening effect is attributed majorly to Al 3 Zr nanoprecipitates along with semi-coherent Al 12 Mn precipitates. • Alloy design tailored for PBF-LB process created Al-Mn-Cr-Zr family of Al alloys. • Alloying elements are supersaturated in solid solution after printing. • On direct ageing, two novel precipitation phenomenon observed. • Feature analysis enabled quantitative precipitation analysis with chemical data.