Investigation of Ti1−x(Zr,Ta,V,W)xB2 and Al3Ti1−x(Zr,V)x grain refiners in additively manufactured Al-2 wt%Cu alloys by a high throughput method

Abstract

Grain refinement plays a central role in powder bed fusion (PBF) additive manufacturing by preventing hot cracking and thus enabling the development of high-strength alloys. However, the mechanism behind grain refinement is not fully understood for conventional casting, nor for PBF. In this work, a high throughput method have been used to produce Al-2 wt%Cu alloys with additions of Ti1-xM(Zr,Ta,V,W)xB2, Al3Ti1-xM(Zr,V)x or AlB2 grain refiners for 0.1 < x < 0.9. It was found that grain size varied with x, M and the sum of Ti + M. Ti1-xMxB2 grain refiners offered no advantage over Al3Ti1-xMx. Overall, Ti and Zr provide the best grain refinement, both as Ti1-xMxB2 and Al3Ti1-xMx. However, Ti1-xZrxB2 had a grain refinement minimum around x = 0.65–0.70. The behavior was similar with Ta, but to a lesser extent. V and W had detrimental effects on grain refinement. Despite the fact that no AlB2 particles were observed, additions of B provided excellent grain refinement and was more efficient than Ti below 0.5at%. Ti1-xMxB2 lattice parameters varied with x and followed Vegard’s law, however, a clear relationship between grain size and epitaxial strain/lattice match could not be established. Similarly, the growth restricting factor alone was not a predictor of grain size.