About this Abstract |
| Meeting |
2027 TMS Annual Meeting & Exhibition
|
| Symposium
|
Aluminum Alloys: Development and Fabrication Symposium and Supplier Forum
|
| Presentation Title |
Linking Analytical Thermal Predictions to Crystallographic Randomization in Laser Powder Bed Fusion of Al7050-AlSi10Mg Alloys |
| Author(s) |
Elifnaz Salamci, Eren Yunus Kalay |
| On-Site Speaker (Planned) |
Elifnaz Salamci |
| Abstract Scope |
High-strength Al-Zn-Mg-Cu alloys are prone to hot cracking during Laser Powder Bed Fusion (LPBF). Al7050 bulk scrap was upcycled by induction-coupled ultrasonic atomization (UA) with AlSi10Mg waste powder to produce LPBF feedstocks. UA produced highly spherical (~0.98) powders with favorable flowability. CALPHAD simulations using Scheil and Scheil-Aziz models predicted a marked reduction in the Crack Susceptibility Coefficient (Kou index), decreasing from 3316-3443 °C in base Al7050 to 1354-2424 °C following AlSi10Mg modification. Measured crack length and count densities of LPBF single-tracks agreed strongly with the calculated Kou indices. EBSD revealed that the AlSi10Mg-modified alloy with the highest Si content (3.09 wt.%) exhibited pronounced cellular refinement, weaker crystallographic texture, and greater crack reduction, whereas the alloy with lower Si content (1.27 wt.% Si) maintained a more stable conduction-mode processing window. This UA-based upcycling strategy enables sustainable production of crack-resistant feedstocks for LPBF. |
| Proceedings Inclusion? |
Planned: Light Metals |
| Keywords |
Aluminum, Recycling and Secondary Recovery |