Mechanical field assisted additive manufacturing of ultrahigh strength aluminum alloy
Additive manufacturing of aluminum (Al) alloys has attracted significant attention in the aerospace industry. However, achieving ultrahigh-strength (>500 MPa) Al alloys remains challenging due to their intrinsic poor printability. Here, we report a novel hybrid additive manufacturing (HAM) approa...
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| Format: | Article |
| Language: | English |
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IOP Publishing
2025-01-01
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| Series: | International Journal of Extreme Manufacturing |
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| Online Access: | https://doi.org/10.1088/2631-7990/adbb95 |
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| author | Wenjie Liu Shengnan Shen Jinlong Meng Jiafeng Xiao Hui Li Hejun Du Qianxing Yin Chaolin Tan |
| author_facet | Wenjie Liu Shengnan Shen Jinlong Meng Jiafeng Xiao Hui Li Hejun Du Qianxing Yin Chaolin Tan |
| author_sort | Wenjie Liu |
| collection | DOAJ |
| description | Additive manufacturing of aluminum (Al) alloys has attracted significant attention in the aerospace industry. However, achieving ultrahigh-strength (>500 MPa) Al alloys remains challenging due to their intrinsic poor printability. Here, we report a novel hybrid additive manufacturing (HAM) approach to process ultrahigh-strength AlMgSc alloy, which combines laser powder bed fusion (LPBF) with interlayer ultrasonic shot peening (USP). The results show that the interlayer ultrasonic shot peening depth reached ∼700 µm, leading to almost full density and residual stress convection from tension to compression. The HAM method promotes equiaxed grain formation and refines grain due to grain recrystallizations. Interestingly, the HAM followed by aging treatment tailors the hierarchically multi-gradient structures, inhibits Mg element intragranular segregation, and promotes the multi-nanoprecipitates (e.g. Al _3 (Sc, Zr) and Al _6 Mn) precipitation. Remarkably, the HAM followed by aging treatment achieves yield strength of 609 MPa and breaks elongation of 7.5%, demonstrating ultrahigh strength and good ductility compared with other Al alloys manufactured by AM and forging as reported in the literature. The strength enhancement mechanisms in this AlMgSc alloy are discussed. The high-density Al _3 (Sc, Zr) precipitates are the main strengthening contributor, and unique hetero-deformation induced (HDI) strengthening (originates from the heterogeneous microstructures) further enhances the strength of the material. This work highlights a novel approach for processing complex-structured ultrahigh strength Al alloy components by hybrid additive manufacturing. |
| format | Article |
| id | doaj-art-e8bc296dea3b490bab3cb356c0a7330c |
| institution | DOAJ |
| issn | 2631-7990 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | IOP Publishing |
| record_format | Article |
| series | International Journal of Extreme Manufacturing |
| spelling | doaj-art-e8bc296dea3b490bab3cb356c0a7330c2025-08-20T03:04:21ZengIOP PublishingInternational Journal of Extreme Manufacturing2631-79902025-01-017404500810.1088/2631-7990/adbb95Mechanical field assisted additive manufacturing of ultrahigh strength aluminum alloyWenjie Liu0https://orcid.org/0009-0007-2078-9263Shengnan Shen1https://orcid.org/0000-0002-3964-8475Jinlong Meng2Jiafeng Xiao3Hui Li4https://orcid.org/0000-0002-4404-8845Hejun Du5Qianxing Yin6Chaolin Tan7https://orcid.org/0000-0003-2029-4600School of Power and Mechanical Engineering, Wuhan University , Wuhan 430072, People’s Republic of China; Singapore Institute of Manufacturing Technology (SIMTech), Agency for Science, Technology and Research (A*STAR) , 5 Cleantech Loop, Singapore 636732, Singapore; Henan Polytechnic University , Jiaozuo 454003, People’s Republic of ChinaSchool of Power and Mechanical Engineering, Wuhan University , Wuhan 430072, People’s Republic of China; The Institute of Technological Sciences, Wuhan University , Wuhan 430072, People’s Republic of ChinaSchool of Power and Mechanical Engineering, Wuhan University , Wuhan 430072, People’s Republic of ChinaSchool of Power and Mechanical Engineering, Wuhan University , Wuhan 430072, People’s Republic of ChinaSchool of Power and Mechanical Engineering, Wuhan University , Wuhan 430072, People’s Republic of China; The Institute of Technological Sciences, Wuhan University , Wuhan 430072, People’s Republic of ChinaNanyang Technological University , 50 Nanyang Avenue, Singapore 639798, SingaporeSchool of Power and Mechanical Engineering, Wuhan University , Wuhan 430072, People’s Republic of ChinaInstitute of Metallic Materials and Intelligent Manufacturing, Soochow University , Suzhou 215137, People’s Republic of China; Singapore Institute of Manufacturing Technology (SIMTech), Agency for Science, Technology and Research (A*STAR) , 5 Cleantech Loop, Singapore 636732, SingaporeAdditive manufacturing of aluminum (Al) alloys has attracted significant attention in the aerospace industry. However, achieving ultrahigh-strength (>500 MPa) Al alloys remains challenging due to their intrinsic poor printability. Here, we report a novel hybrid additive manufacturing (HAM) approach to process ultrahigh-strength AlMgSc alloy, which combines laser powder bed fusion (LPBF) with interlayer ultrasonic shot peening (USP). The results show that the interlayer ultrasonic shot peening depth reached ∼700 µm, leading to almost full density and residual stress convection from tension to compression. The HAM method promotes equiaxed grain formation and refines grain due to grain recrystallizations. Interestingly, the HAM followed by aging treatment tailors the hierarchically multi-gradient structures, inhibits Mg element intragranular segregation, and promotes the multi-nanoprecipitates (e.g. Al _3 (Sc, Zr) and Al _6 Mn) precipitation. Remarkably, the HAM followed by aging treatment achieves yield strength of 609 MPa and breaks elongation of 7.5%, demonstrating ultrahigh strength and good ductility compared with other Al alloys manufactured by AM and forging as reported in the literature. The strength enhancement mechanisms in this AlMgSc alloy are discussed. The high-density Al _3 (Sc, Zr) precipitates are the main strengthening contributor, and unique hetero-deformation induced (HDI) strengthening (originates from the heterogeneous microstructures) further enhances the strength of the material. This work highlights a novel approach for processing complex-structured ultrahigh strength Al alloy components by hybrid additive manufacturing.https://doi.org/10.1088/2631-7990/adbb95additive manufacturingAlMgSc alloyhybrid additive manufacturinggradient structuresdislocation evolutionmechanical properties |
| spellingShingle | Wenjie Liu Shengnan Shen Jinlong Meng Jiafeng Xiao Hui Li Hejun Du Qianxing Yin Chaolin Tan Mechanical field assisted additive manufacturing of ultrahigh strength aluminum alloy International Journal of Extreme Manufacturing additive manufacturing AlMgSc alloy hybrid additive manufacturing gradient structures dislocation evolution mechanical properties |
| title | Mechanical field assisted additive manufacturing of ultrahigh strength aluminum alloy |
| title_full | Mechanical field assisted additive manufacturing of ultrahigh strength aluminum alloy |
| title_fullStr | Mechanical field assisted additive manufacturing of ultrahigh strength aluminum alloy |
| title_full_unstemmed | Mechanical field assisted additive manufacturing of ultrahigh strength aluminum alloy |
| title_short | Mechanical field assisted additive manufacturing of ultrahigh strength aluminum alloy |
| title_sort | mechanical field assisted additive manufacturing of ultrahigh strength aluminum alloy |
| topic | additive manufacturing AlMgSc alloy hybrid additive manufacturing gradient structures dislocation evolution mechanical properties |
| url | https://doi.org/10.1088/2631-7990/adbb95 |
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