Evaluation of the segregation in printed mono-sized Al-In alloy droplets

Abstract

Monotectic alloys, with a focus on lightweight and multifaceted aluminum-indium alloys, possess extensive applications and considerable potential for growth within high-tech sectors. This study addresses a crucial gap within additive manufacturing research pertaining to monotectic alloys, a matter of significance in the context of Industry 4.0. We investigate the application of Uniform Metal Droplet Printing Technology (UMDPT) to address the segregation issue prevalent during the solidification process of these alloys, an impediment compromising their resilience and longevity. The research not only advocates for the use of UMDPT in producing monotectic alloys, but also offers valuable insights into the mechanisms of segregation inhibition, thereby broadening the understanding of additive manufacturing technology. Experimental results indicate that this technology can efficaciously inhibit the segregation of the indium-rich secondary phase during the solidification of the aluminum-indium alloy. The conducted experiments utilized droplets at 1073 K with a nozzle diameter of 500 μm and demonstrated a uniform dispersion of the secondary phase, with a size of 0.5 μm and a variation coefficient of 0.375. This groundbreaking research outcome bears considerable implications for further advancements in this domain and fosters the evolution of more efficient manufacturing methodologies.