Nanoparticle-enabled additive manufacturing of high strength 6061 aluminum alloy via Laser Powder Bed Fusion

IF 1.9 Q3 ENGINEERING, MANUFACTURING Manufacturing Letters Pub Date : 2024-10-01 DOI:10.1016/j.mfglet.2024.09.093

Tianqi Zheng , Changyu Ma , Alexander Killips , Bingbing Li , Xiaochun Li

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Abstract

Wrought aluminum alloy AA6061 is widely used in automotive, aerospace, and other industries due to its good properties, including high strength, excellent corrosion resistance, and good weldability. However, when using Laser Powder Bed Fusion (LPBF) for AA6061, hot cracking becomes a serious problem. In this work, AA6061 powder with internally dispersed nanoparticles has been adopted in a LPBF process. Through optimization of printing parameters, components with minimal porosity (less than 0.5 %) have been successfully produced without cracks. Additionally, by employing a chessboard printing strategy to create finely detailed cellular and grain structures, we have achieved significantly enhanced mechanical properties in its as-printed state for AA6061. These components exhibit an impressive yield strength (YS) of 233 MPa and ultimate tensile strength (UTS) of 310 MPa while maintaining a ductility of approximately 10 %. This performance surpasses that of commercial AA6061 and other Al-Si alloys, establishing it as a high-strength material suitable for various applications.

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通过激光粉末床熔融技术实现高强度 6061 铝合金的纳米粒子增材制造

锻造铝合金 AA6061 具有强度高、耐腐蚀性强、可焊性好等优良特性，因此被广泛应用于汽车、航空航天和其他行业。然而，在对 AA6061 采用激光粉末床熔化 (LPBF) 时，热裂纹成为一个严重问题。在这项工作中，AA6061 粉末内部分散了纳米颗粒，被应用于 LPBF 工艺中。通过优化印刷参数，成功生产出孔隙率最小（小于 0.5%）且无裂纹的部件。此外，通过采用棋盘式印刷策略来创建精细的蜂窝和晶粒结构，我们还显著提高了 AA6061 在印刷状态下的机械性能。这些部件的屈服强度（YS）达到了惊人的 233 兆帕，极限拉伸强度（UTS）达到了 310 兆帕，同时保持了约 10% 的延展性。这一性能超过了商用 AA6061 和其他铝硅合金，使其成为适合各种应用的高强度材料。

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