This study investigates the mechanical properties of an Al-Ni-Cu-Fe alloy fabricated using laser powder bed fusion (LPBF) technology, evaluated at temperatures ranging from room temperature to 300°C under various strain rates for potential aerospace and automotive applications. Aluminum alloys often face the challenges of maintaining high-temperature strength and stability, limiting their use in demanding environments. The results demonstrate that the LPBF Al-Ni-Cu-Fe alloy maintains strength above 300 MPa at standard strain rates and reaches up to 400 MPa at high strain rates at 300°C, indicating its suitability for lightweight, high-strength vehicles and thermal engineering systems. The high-temperature strengthening mechanisms are attributed to Al9FeNi submicron cellular eutectic walls that impede dislocation motion and precipitation strengthening from Al2Cu. Fracture analysis reveals that localized brittleness limits elongation to 3% at room temperature, with deformation distributed between coarse-grained (CG) and fine-grained (FG) regions. At elevated temperatures (300°C), partial homogenization of FG regions reduces melt pool constraints, promoting local deformation. Therefore, ductility increases significantly under high strain rates as the dispersed Al9FeNi phases become less effective in resisting instantaneous stresses, allowing deformation to overcome melt pool boundaries. At extreme strain rates during impact testing, twinning becomes the dominant deformation mechanism, contrasting with tensile testing. These findings confirm the potential of the LPBF Al-Ni-Cu-Fe alloy as a heat-resistant printed aluminum alloy for high-temperature applications and provide valuable insights into fracture mechanisms within the bimodal microstructure, guiding future alloy optimization.
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