About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
Aluminum Alloys: Development and Manufacturing
|
| Presentation Title |
Tailoring Microstructure and Defects in AA6061 via Laser Modulation in Powder Bed Fusion |
| Author(s) |
Can Sun, Sivaji Karna, Rimah Al-Aridi, Andrew J. Gross, Daniel Morrall, Timothy Krentz, Dale Hitchcock, Lang Yuan |
| On-Site Speaker (Planned) |
Can Sun |
| Abstract Scope |
AA6061 is prone to porosity and solidification cracking under rapid solidification conditions, presenting significant processing challenges in additive manufacturing. In this study, pulsed laser powder bed fusion process parameters, specifically frequency and duty cycle, have been systematically investigated to engineer the microstructure and defects of AA6061, including grains, subgrains, precipitates, porosity and cracking. High frequency with a low duty cycle led to multiple melt pool boundaries within a single melt track, refined grains, uniform subgrains, and reduced cracks. In contrast, high frequency with a high duty cycle resulted in a continuous melt track with coarse grains due to sustained melting. This processing condition also reduced porosity and cracks compared to low-duty-cycle laser modulations. Tensile testing was conducted to assess the mechanical properties. These findings signify that the application of modulated laser processing is an effective strategy for controlling microstructure and minimizing defects in additively manufactured aluminum alloys. |
| Proceedings Inclusion? |
Planned: Light Metals |
| Keywords |
Additive Manufacturing, Aluminum, Characterization |