Microstructure and mechanical properties of a hypereutectic Al–Si–Cu alloy manufactured by laser powder bed fusion

Abstract

A novel Al–Si–Cu alloy was designed for additive manufacturing of automotive components, such as pistons and supercharger rotors, requiring a combination of elevated temperature properties and high cycle fatigue strength. The alloy was designed with an Al–Si hypereutectic chemistry to exploit the formation of primary Si nucleants to enable an equiaxed as-printed microstructure during laser powder bed fusion (LPBF). The alloy design space was assessed using a combined integrated computational materials engineering (ICME) approach with melt-spinning experiments to select a chemistry exhibiting primary Si nucleants acting as heterogeneous grain nucleation sites. Scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) of the LPBF as-printed samples revealed primary Si particles with a fully equiaxed grain structure and no apparent texturing as evaluated using electron backscatter diffraction (EBSD). High-resolution scanning transmission electron microscopy (STEM) revealed sub-micron Si particles and Al2Cu θ-phase precipitates which result in enhanced room and elevated temperature mechanical strength (room temperature: UTS: 449 ± 10 MPa, YS: 336 ± 12 MPa) as compared to commercial Al10SiMg (UTS: 417 ± 3 MPa, YS: 236 ± 6 MPa).