Effective Platform Heating for Laser Powder Bed Fusion of an Al-Mn-Sc-Based Alloy
Platform heating is one of the effective strategies used in laser powder bed fusion (LPBF) to avoid cracking during manufacturing, especially when building relatively large-size components, as it removes significant process-induced residual strains. In this work, we propose a novel and simple method...
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MDPI AG
2023-12-01
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| Series: | Materials |
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| Online Access: | https://www.mdpi.com/1996-1944/16/24/7586 |
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| author | Dina Bayoumy Torben Boll Amal Shaji Karapuzha Xinhua Wu Yuman Zhu Aijun Huang |
| author_facet | Dina Bayoumy Torben Boll Amal Shaji Karapuzha Xinhua Wu Yuman Zhu Aijun Huang |
| author_sort | Dina Bayoumy |
| collection | DOAJ |
| description | Platform heating is one of the effective strategies used in laser powder bed fusion (LPBF) to avoid cracking during manufacturing, especially when building relatively large-size components, as it removes significant process-induced residual strains. In this work, we propose a novel and simple method to spare the elaborate post-processing heat treatment typically needed for LPBF Al-Sc alloys without compromising the mechanical properties. We systematically investigated the effects of LPBF platform heating at 200 °C on the residual stress relief, microstructure, and mechanical performance of a high-strength Al-Mn-Sc alloy. The results reveal that LPBF platform heating at 200 °C is sufficient to largely relieve the process-induced residual stresses compared to parts built on an unheated 35 °C platform. Meanwhile, the platform heating triggered the dynamic precipitation of uniformly dispersed (1.5–2 nm) Sc-rich nano-clusters. Their formation in a high number density (1.75 × 10<sup>24</sup> m<sup>−3</sup>) resulted in a ~20% improvement in tensile yield strength (522 MPa) compared to the build on the unheated platform, without sacrificing the ductility (up to 18%). The improved mechanical properties imply that platform heating at 200 °C can strengthen the LPBF-synthesised Sc-containing Al alloys via in situ aging, which is further justified by an in situ measurement study revealing that the developing temperatures in the LPBF part are within the aging temperature range of Al-Sc alloys. Without any post-LPBF treatments, these mechanical properties have proven better than those of most Al-Sc alloys through long-time post-LPBF heat treatment. |
| first_indexed | 2024-03-08T20:33:35Z |
| format | Article |
| id | doaj.art-19f1d38b2cb9436ca56453a6dea3bc80 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-08T20:33:35Z |
| publishDate | 2023-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-19f1d38b2cb9436ca56453a6dea3bc802023-12-22T14:22:44ZengMDPI AGMaterials1996-19442023-12-011624758610.3390/ma16247586Effective Platform Heating for Laser Powder Bed Fusion of an Al-Mn-Sc-Based AlloyDina Bayoumy0Torben Boll1Amal Shaji Karapuzha2Xinhua Wu3Yuman Zhu4Aijun Huang5Monash Centre for Additive Manufacturing, 15–17 Normanby Rd, Notting Hill, VIC 3168, AustraliaKarlsruhe Nano Micro Facility (KNMF), Karlsruhe Institute of Technology (KIT), Hermann-von-Helmholtz-Platz 1, D-76344 Eggenstein-Leopoldshafen, GermanyMonash Centre for Additive Manufacturing, 15–17 Normanby Rd, Notting Hill, VIC 3168, AustraliaMonash Centre for Additive Manufacturing, 15–17 Normanby Rd, Notting Hill, VIC 3168, AustraliaMonash Centre for Additive Manufacturing, 15–17 Normanby Rd, Notting Hill, VIC 3168, AustraliaMonash Centre for Additive Manufacturing, 15–17 Normanby Rd, Notting Hill, VIC 3168, AustraliaPlatform heating is one of the effective strategies used in laser powder bed fusion (LPBF) to avoid cracking during manufacturing, especially when building relatively large-size components, as it removes significant process-induced residual strains. In this work, we propose a novel and simple method to spare the elaborate post-processing heat treatment typically needed for LPBF Al-Sc alloys without compromising the mechanical properties. We systematically investigated the effects of LPBF platform heating at 200 °C on the residual stress relief, microstructure, and mechanical performance of a high-strength Al-Mn-Sc alloy. The results reveal that LPBF platform heating at 200 °C is sufficient to largely relieve the process-induced residual stresses compared to parts built on an unheated 35 °C platform. Meanwhile, the platform heating triggered the dynamic precipitation of uniformly dispersed (1.5–2 nm) Sc-rich nano-clusters. Their formation in a high number density (1.75 × 10<sup>24</sup> m<sup>−3</sup>) resulted in a ~20% improvement in tensile yield strength (522 MPa) compared to the build on the unheated platform, without sacrificing the ductility (up to 18%). The improved mechanical properties imply that platform heating at 200 °C can strengthen the LPBF-synthesised Sc-containing Al alloys via in situ aging, which is further justified by an in situ measurement study revealing that the developing temperatures in the LPBF part are within the aging temperature range of Al-Sc alloys. Without any post-LPBF treatments, these mechanical properties have proven better than those of most Al-Sc alloys through long-time post-LPBF heat treatment.https://www.mdpi.com/1996-1944/16/24/7586additive manufacturingaluminium alloysLPBF |
| spellingShingle | Dina Bayoumy Torben Boll Amal Shaji Karapuzha Xinhua Wu Yuman Zhu Aijun Huang Effective Platform Heating for Laser Powder Bed Fusion of an Al-Mn-Sc-Based Alloy Materials additive manufacturing aluminium alloys LPBF |
| title | Effective Platform Heating for Laser Powder Bed Fusion of an Al-Mn-Sc-Based Alloy |
| title_full | Effective Platform Heating for Laser Powder Bed Fusion of an Al-Mn-Sc-Based Alloy |
| title_fullStr | Effective Platform Heating for Laser Powder Bed Fusion of an Al-Mn-Sc-Based Alloy |
| title_full_unstemmed | Effective Platform Heating for Laser Powder Bed Fusion of an Al-Mn-Sc-Based Alloy |
| title_short | Effective Platform Heating for Laser Powder Bed Fusion of an Al-Mn-Sc-Based Alloy |
| title_sort | effective platform heating for laser powder bed fusion of an al mn sc based alloy |
| topic | additive manufacturing aluminium alloys LPBF |
| url | https://www.mdpi.com/1996-1944/16/24/7586 |
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