Processability and Optimization of Laser Parameters for Densification of Hypereutectic Al–Fe Binary Alloy Manufactured by Laser Powder Bed Fusion

Wang, Wenyuan; Takata, Naoki; Suzuki, Asuka; Kobashi, Makoto; Kato, Masaki

doi:10.3390/cryst11030320

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Processability and Optimization of Laser Parameters for Densification of Hypereutectic Al–Fe Binary Alloy Manufactured by Laser Powder Bed Fusion

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Department of Materials Process Engineering, Graduate School of Engineering, Nagoya University, Furo-cho, Chikusa-ku, Nagoya 464-8603, Japan

Aichi Center for Industry and Science Technology, 1267-1 Akiai, Yakusa-cho, Toyota 470-0356, Japan

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Academic Editor: Umberto Prisco

Crystals 2021, 11(3), 320; https://doi.org/10.3390/cryst11030320

Received: 5 March 2021 / Revised: 20 March 2021 / Accepted: 22 March 2021 / Published: 23 March 2021

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Abstract

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 (P) and scan speed (v). 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 P = 77–128 W and v = 0.4–0.8 ms⁻¹ was found for manufacturing macroscopically crack-free samples. A higher v and P 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-Al₁₃Fe₄ phase, resulting in low L-PBF processability of Al–15%Fe alloy. The deposited energy density model (using P·v⁻¹^/2) 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 P·v⁻¹), 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–Al₁₃Fe₄ phases localized at melt pool boundaries. These results provide insights into achieving sufficient L-PBF processability for manufacturing dense Al–Fe binary alloy samples. View Full-Text

Keywords: additive manufacturing; selective laser melting; aluminum alloys; Al–Fe intermetallics; process parameters

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Wang, W.; Takata, N.; Suzuki, A.; Kobashi, M.; Kato, M. Processability and Optimization of Laser Parameters for Densification of Hypereutectic Al–Fe Binary Alloy Manufactured by Laser Powder Bed Fusion. Crystals 2021, 11, 320. https://doi.org/10.3390/cryst11030320

AMA Style

Wang W, Takata N, Suzuki A, Kobashi M, Kato M. Processability and Optimization of Laser Parameters for Densification of Hypereutectic Al–Fe Binary Alloy Manufactured by Laser Powder Bed Fusion. Crystals. 2021; 11(3):320. https://doi.org/10.3390/cryst11030320

Chicago/Turabian Style

Wang, Wenyuan, Naoki Takata, Asuka Suzuki, Makoto Kobashi, and Masaki Kato. 2021. "Processability and Optimization of Laser Parameters for Densification of Hypereutectic Al–Fe Binary Alloy Manufactured by Laser Powder Bed Fusion" Crystals 11, no. 3: 320. https://doi.org/10.3390/cryst11030320

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Processability and Optimization of Laser Parameters for Densification of Hypereutectic Al–Fe Binary Alloy Manufactured by Laser Powder Bed Fusion

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