Abstract
The feasibility of using laser direct energy deposition (DED) additive manufacturing (AM) to synthesize a commercial, aluminum-manganese alloy of the 3000 series was evaluated by comparing the microstructures of AM and direct-chill (DC) cast alloys. The purpose of this work was to establish a baseline for accelerating Al alloy discovery using combinatorial materials synthesis. Feedstock alloy powder was prepared by mixing pure metal element or binary alloy powders via ball-milling and fabricating bulk samples using laser DED AM. Compositional accuracy of both powder feedstock and laser DED AM samples was controlled within 10% of the target. The effect of homogenization on the evolution of second-phase particles as a function of temperature and time was found to be similar in both laser DED AM and DC-cast materials.
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