LPBF-Formed 2024Al Alloys: Process, Microstructure, Properties, and Thermal Cracking Behavior
2024Al is an Al-Cu-Mg series heat-treatable aluminum alloy with high strength and excellent damage resistance. To obtain a high-performance target component of LPBF-formed 2024Al, the effect of process parameters on density, microstructure, and performance is systematically investigated and the ther...
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MDPI AG
2023-01-01
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| Series: | Metals |
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| Online Access: | https://www.mdpi.com/2075-4701/13/2/268 |
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| author | Sen Yao Jiajian Wang Min Li Zhen Chen Bingheng Lu Song Shen Yao Li |
| author_facet | Sen Yao Jiajian Wang Min Li Zhen Chen Bingheng Lu Song Shen Yao Li |
| author_sort | Sen Yao |
| collection | DOAJ |
| description | 2024Al is an Al-Cu-Mg series heat-treatable aluminum alloy with high strength and excellent damage resistance. To obtain a high-performance target component of LPBF-formed 2024Al, the effect of process parameters on density, microstructure, and performance is systematically investigated and the thermal cracking phenomenon is analyzed in detail. The results reveal that the optimization of process parameters can suppress the cracks generated during the LPBF forming of 2024Al to a certain extent. When the laser energy density is 741 J/mm<sup>3</sup>, the maximum density reaches 99.77%, whereas the tensile strength and elongation reach 330 ± 7 MPa and 9 ± 0.6%, respectively. Owing to the high Cu and Mg contents in 2024Al, the transverse strain rate of columnar grains during LPBF forming is easily higher than the sum of the transverse expansion rate of grains and the liquid phase filling rate at grain boundaries, resulting in strong thermal crack sensitivity. In addition, an extremely high cooling rate (−10<sup>8</sup> K/s) and heat input during LPBF forming reduce the liquid phase filling rate at grain boundaries to further aggravate the thermal cracking tendency. The current study provides experimental guidance for the preparation of high-quality, crack-less, or even crack-free 2024Al alloys. |
| first_indexed | 2024-03-11T08:25:09Z |
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| id | doaj.art-67d009c5a0334f31b252eada2b054289 |
| institution | Directory Open Access Journal |
| issn | 2075-4701 |
| language | English |
| last_indexed | 2024-03-11T08:25:09Z |
| publishDate | 2023-01-01 |
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| spelling | doaj.art-67d009c5a0334f31b252eada2b0542892023-11-16T22:07:00ZengMDPI AGMetals2075-47012023-01-0113226810.3390/met13020268LPBF-Formed 2024Al Alloys: Process, Microstructure, Properties, and Thermal Cracking BehaviorSen Yao0Jiajian Wang1Min Li2Zhen Chen3Bingheng Lu4Song Shen5Yao Li6State Key Laboratory of Manufacturing System Engineering, Xi’an Jiaotong University, Xi’an 710049, ChinaState Key Laboratory of Manufacturing System Engineering, Xi’an Jiaotong University, Xi’an 710049, ChinaState Key Laboratory for Mechanical Behaviour of Materials, Xi’an Jiaotong University, Xi’an 710049, ChinaState Key Laboratory of Manufacturing System Engineering, Xi’an Jiaotong University, Xi’an 710049, ChinaState Key Laboratory of Manufacturing System Engineering, Xi’an Jiaotong University, Xi’an 710049, ChinaSchool of Mechanical Engineering, Xi’an University of Science and Technology, Xi’an 710054, ChinaSchool of Material Science and Engineering, Chang’an University, Xi’an 710064, China2024Al is an Al-Cu-Mg series heat-treatable aluminum alloy with high strength and excellent damage resistance. To obtain a high-performance target component of LPBF-formed 2024Al, the effect of process parameters on density, microstructure, and performance is systematically investigated and the thermal cracking phenomenon is analyzed in detail. The results reveal that the optimization of process parameters can suppress the cracks generated during the LPBF forming of 2024Al to a certain extent. When the laser energy density is 741 J/mm<sup>3</sup>, the maximum density reaches 99.77%, whereas the tensile strength and elongation reach 330 ± 7 MPa and 9 ± 0.6%, respectively. Owing to the high Cu and Mg contents in 2024Al, the transverse strain rate of columnar grains during LPBF forming is easily higher than the sum of the transverse expansion rate of grains and the liquid phase filling rate at grain boundaries, resulting in strong thermal crack sensitivity. In addition, an extremely high cooling rate (−10<sup>8</sup> K/s) and heat input during LPBF forming reduce the liquid phase filling rate at grain boundaries to further aggravate the thermal cracking tendency. The current study provides experimental guidance for the preparation of high-quality, crack-less, or even crack-free 2024Al alloys.https://www.mdpi.com/2075-4701/13/2/268laser powder bed fusion (LPBF)2024Alcrackmicrostructure |
| spellingShingle | Sen Yao Jiajian Wang Min Li Zhen Chen Bingheng Lu Song Shen Yao Li LPBF-Formed 2024Al Alloys: Process, Microstructure, Properties, and Thermal Cracking Behavior Metals laser powder bed fusion (LPBF) 2024Al crack microstructure |
| title | LPBF-Formed 2024Al Alloys: Process, Microstructure, Properties, and Thermal Cracking Behavior |
| title_full | LPBF-Formed 2024Al Alloys: Process, Microstructure, Properties, and Thermal Cracking Behavior |
| title_fullStr | LPBF-Formed 2024Al Alloys: Process, Microstructure, Properties, and Thermal Cracking Behavior |
| title_full_unstemmed | LPBF-Formed 2024Al Alloys: Process, Microstructure, Properties, and Thermal Cracking Behavior |
| title_short | LPBF-Formed 2024Al Alloys: Process, Microstructure, Properties, and Thermal Cracking Behavior |
| title_sort | lpbf formed 2024al alloys process microstructure properties and thermal cracking behavior |
| topic | laser powder bed fusion (LPBF) 2024Al crack microstructure |
| url | https://www.mdpi.com/2075-4701/13/2/268 |
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