| Abstract Scope |
Additive manufacturing makes aluminum alloys attractive for aerospace and automotive parts because they can be lightweight, complex, and material-efficient. However, cracking and unstable solidification are still major barriers to broader use. In this study, Aheadd® CP1, an Al-Fe-Zr alloy developed for additive manufacturing, was deposited onto AA6061 substrates to evaluate the effects of laser power, scanning speed, and substrate preheating on build quality and microstructural development. Without substrate preheating, the deposits showed a narrow range of process parameters that produced acceptable deposition quality. Surface morphology and resultant deposition geometry are reliant on the applied laser energy density. Higher power improved layer continuity and melt-pool stability, while lower power produced a rougher and less uniform surface. These preliminary results suggest that CP1 can be processed successfully within the selected DED window. Ongoing characterization will further examine phase evolution and strengthening mechanisms and help establish process-structure-property relationships for crack-resistant aluminum additive manufacturing.
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