Processability and Optimization of Laser Parameters for Densification of Hypereutectic Al–Fe Binary Alloy Manufactured by Laser Powder Bed Fusion
Centimeter-sized samples of hypereutectic Al–15 mass% Fe alloy were manufactured by a laser powder bed fusion (L-PBF) process while systematically varying laser power (<i>P</i>) and scan speed (<i>v</i>). The effects on relative density and melt pool depth of L-PBF-manufactur...
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MDPI AG
2021-03-01
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| Online Access: | https://www.mdpi.com/2073-4352/11/3/320 |
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| author | Wenyuan Wang Naoki Takata Asuka Suzuki Makoto Kobashi Masaki Kato |
| author_facet | Wenyuan Wang Naoki Takata Asuka Suzuki Makoto Kobashi Masaki Kato |
| author_sort | Wenyuan Wang |
| collection | DOAJ |
| description | Centimeter-sized samples of hypereutectic Al–15 mass% Fe alloy were manufactured by a laser powder bed fusion (L-PBF) process while systematically varying laser power (<i>P</i>) and scan speed (<i>v</i>). The effects on relative density and melt pool depth of L-PBF-manufactured samples were investigated. In comparison with other Al alloys, a small laser process window of <i>P</i> = 77–128 W and <i>v</i> = 0.4–0.8 ms<sup>−1</sup> was found for manufacturing macroscopically crack-free samples. A higher <i>v</i> and <i>P</i> led to the creation of macroscopic cracks propagating parallel to the powder-bed plane. These cracks preferentially propagated along the melt pool boundaries decorated with brittle θ-Al<sub>13</sub>Fe<sub>4</sub> phase, resulting in low L-PBF processability of Al–15%Fe alloy. The deposited energy density model (using <i>P</i>·<i>v</i><sup>−1</sup><sup>/2</sup>) would be useful for identifying the optimum L-PBF process conditions towards densification of Al–15%Fe alloy samples, in comparison with the volumetric energy density (using <i>P</i>·<i>v</i><sup>−1</sup>), however, the validity of the model was reduced for this alloy in comparison with other alloys with high thermal conductivities. This is likely due to inhomogeneous microstructures having numerous coarsened θ–Al<sub>13</sub>Fe<sub>4</sub> phases localized at melt pool boundaries. These results provide insights into achieving sufficient L-PBF processability for manufacturing dense Al–Fe binary alloy samples. |
| first_indexed | 2024-03-10T12:58:07Z |
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| last_indexed | 2024-03-10T12:58:07Z |
| publishDate | 2021-03-01 |
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| spelling | doaj.art-76ad29cb47724eacb71e2d57d82c2fc32023-11-21T11:45:04ZengMDPI AGCrystals2073-43522021-03-0111332010.3390/cryst11030320Processability and Optimization of Laser Parameters for Densification of Hypereutectic Al–Fe Binary Alloy Manufactured by Laser Powder Bed FusionWenyuan Wang0Naoki Takata1Asuka Suzuki2Makoto Kobashi3Masaki Kato4Department of Materials Process Engineering, Graduate School of Engineering, Nagoya University, Furo-cho, Chikusa-ku, Nagoya 464-8603, JapanDepartment of Materials Process Engineering, Graduate School of Engineering, Nagoya University, Furo-cho, Chikusa-ku, Nagoya 464-8603, JapanDepartment of Materials Process Engineering, Graduate School of Engineering, Nagoya University, Furo-cho, Chikusa-ku, Nagoya 464-8603, JapanDepartment of Materials Process Engineering, Graduate School of Engineering, Nagoya University, Furo-cho, Chikusa-ku, Nagoya 464-8603, JapanAichi Center for Industry and Science Technology, 1267-1 Akiai, Yakusa-cho, Toyota 470-0356, JapanCentimeter-sized samples of hypereutectic Al–15 mass% Fe alloy were manufactured by a laser powder bed fusion (L-PBF) process while systematically varying laser power (<i>P</i>) and scan speed (<i>v</i>). The effects on relative density and melt pool depth of L-PBF-manufactured samples were investigated. In comparison with other Al alloys, a small laser process window of <i>P</i> = 77–128 W and <i>v</i> = 0.4–0.8 ms<sup>−1</sup> was found for manufacturing macroscopically crack-free samples. A higher <i>v</i> and <i>P</i> led to the creation of macroscopic cracks propagating parallel to the powder-bed plane. These cracks preferentially propagated along the melt pool boundaries decorated with brittle θ-Al<sub>13</sub>Fe<sub>4</sub> phase, resulting in low L-PBF processability of Al–15%Fe alloy. The deposited energy density model (using <i>P</i>·<i>v</i><sup>−1</sup><sup>/2</sup>) would be useful for identifying the optimum L-PBF process conditions towards densification of Al–15%Fe alloy samples, in comparison with the volumetric energy density (using <i>P</i>·<i>v</i><sup>−1</sup>), however, the validity of the model was reduced for this alloy in comparison with other alloys with high thermal conductivities. This is likely due to inhomogeneous microstructures having numerous coarsened θ–Al<sub>13</sub>Fe<sub>4</sub> phases localized at melt pool boundaries. These results provide insights into achieving sufficient L-PBF processability for manufacturing dense Al–Fe binary alloy samples.https://www.mdpi.com/2073-4352/11/3/320additive manufacturingselective laser meltingaluminum alloysAl–Fe intermetallicsprocess parameters |
| spellingShingle | Wenyuan Wang Naoki Takata Asuka Suzuki Makoto Kobashi Masaki Kato Processability and Optimization of Laser Parameters for Densification of Hypereutectic Al–Fe Binary Alloy Manufactured by Laser Powder Bed Fusion Crystals additive manufacturing selective laser melting aluminum alloys Al–Fe intermetallics process parameters |
| title | Processability and Optimization of Laser Parameters for Densification of Hypereutectic Al–Fe Binary Alloy Manufactured by Laser Powder Bed Fusion |
| title_full | Processability and Optimization of Laser Parameters for Densification of Hypereutectic Al–Fe Binary Alloy Manufactured by Laser Powder Bed Fusion |
| title_fullStr | Processability and Optimization of Laser Parameters for Densification of Hypereutectic Al–Fe Binary Alloy Manufactured by Laser Powder Bed Fusion |
| title_full_unstemmed | Processability and Optimization of Laser Parameters for Densification of Hypereutectic Al–Fe Binary Alloy Manufactured by Laser Powder Bed Fusion |
| title_short | Processability and Optimization of Laser Parameters for Densification of Hypereutectic Al–Fe Binary Alloy Manufactured by Laser Powder Bed Fusion |
| title_sort | processability and optimization of laser parameters for densification of hypereutectic al fe binary alloy manufactured by laser powder bed fusion |
| topic | additive manufacturing selective laser melting aluminum alloys Al–Fe intermetallics process parameters |
| url | https://www.mdpi.com/2073-4352/11/3/320 |
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