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Meeting 2026 TMS Annual Meeting & Exhibition
Symposium Thermodynamics and Kinetics of Alloys IV
Presentation Title High throughput validation of low-cost, high-strength Al-alloys for additive manufacturing via laser scanning strategies
Author(s) Benjamin M. Glaser, S. Mohadeseh Taheri-Mousavi
On-Site Speaker (Planned) Benjamin M. Glaser
Abstract Scope Printable aluminum alloys are in high-demand for automotive and aerospace industries due to their high strength-to-density ratio and low cost. We discovered a pathway to strengthening using metastable phase features formed during rapid solidification, which offer high room-temperature strengthening, and react under aging to form nano-L12 particles that are stable at high-temperature. We used CALPHAD-based ICME simulations and Bayesian optimization to discover three new alloys leveraging these mechanisms: a high-temperature design that has 95% strength of a benchmark alloy with 15% cost savings; an extreme low-cost design with benchmark strength and 80% cost savings; a high-performance design with 10x increase in strengthening features and 60% cost savings. We used a rapid experimental workflow to validate these designs by casting homogeneous samples, then rolling, laser scanning, and mechanically testing the alloys. We leveraged this workflow to rapidly optimize the final alloy compositions and produced gas atomized powder samples for final testing.
Proceedings Inclusion? Planned:
Keywords Additive Manufacturing, Aluminum, ICME

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