Mar, 2021
Processability and Optimization of Laser Parameters for Densification of Hypereutectic Al-Fe Binary Alloy Manufactured by Laser Powder Bed Fusion
CRYSTALS
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- Volume
- 11
- Number
- 3
- Language
- Japanese
- Publishing type
- Research paper (scientific journal)
- DOI
- 10.3390/cryst11030320
- Publisher
- MDPI
Centimeter-sized samples of hypereutectic Al-15 mass% Fe alloy were manufactured by a laser powder bed fusion (L-PBF) process while systematically varying laser power (P) and scan speed (v). The effects on relative density and melt pool depth of L-PBF-manufactured samples were investigated. In comparison with other Al alloys, a small laser process window of P = 77-128 W and v = 0.4-0.8 ms(-1) was found for manufacturing macroscopically crack-free samples. A higher v and P led to the creation of macroscopic cracks propagating parallel to the powder-bed plane. These cracks preferentially propagated along the melt pool boundaries decorated with brittle theta-Al13Fe4 phase, resulting in low L-PBF processability of Al-15%Fe alloy. The deposited energy density model (using P center dot v(-1)(/2)) would be useful for identifying the optimum L-PBF process conditions towards densification of Al-15%Fe alloy samples, in comparison with the volumetric energy density (using P center dot v(-1)), however, the validity of the model was reduced for this alloy in comparison with other alloys with high thermal conductivities. This is likely due to inhomogeneous microstructures having numerous coarsened theta-Al13Fe4 phases localized at melt pool boundaries. These results provide insights into achieving sufficient L-PBF processability for manufacturing dense Al-Fe binary alloy samples.
- Link information
- ID information
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- DOI : 10.3390/cryst11030320
- ISSN : 2073-4352
- eISSN : 2073-4352
- Web of Science ID : WOS:000635247600001