About this Abstract |
Meeting |
MS&T21: Materials Science & Technology
|
Symposium
|
Additive Manufacturing of Metals: Microstructure, Properties and Alloy Development
|
Presentation Title |
Process Optimization and Microstructural Analysis for Laser Powder Bed Fusion of AlMgZr Alloy |
Author(s) |
Nellie Pestian, Thomas Carmody, Dan P. Satko, Evan Diewald, Christian Gobert, Anthony Rollett, Jack Beuth, Ayman Salem, Nam Phan, Jan Kasprzak |
On-Site Speaker (Planned) |
Nellie Pestian |
Abstract Scope |
The utilization of additively-manufactured (AM) aluminum parts for aerospace applications requires the avoidance of hot tearing cracks that plague the AM of conventional alloys (e.g. Al 6xxx and 7xxx series). While various nucleates have been demonstrated to enable crack-free AM of high-strength Al alloys, Zr-based alloys are capturing a lot of attention due to lower cost. In this presentation, we introduce a laser powder bed fusion (LPBF) process map for a novel AlMgZr alloy. This multi-dimensional process map includes the effect of laser power, scan speed, hatch spacing, and spot size. A model-based design of experiments was used to predict the volume of the melt pool using analytical and numerical predictions based on a volumetric heat source model. Microstructure and defect evolution were captured in cuboid coupon samples using conventional metallography and microCT. A process window for minimum defects is presented with a path for ICME-based scaling to part level. |