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Meeting 2023 TMS Annual Meeting & Exhibition
Symposium Additive Manufacturing: Materials Design and Alloy Development V – Design Fundamentals
Presentation Title Hypereutectic Al-Si-Cu Alloy for Laser Powder Bed Fusion
Author(s) Andrew Bobel, Yoojin Kim, Lee Casalena, Anil K Sachdev
On-Site Speaker (Planned) Andrew Bobel
Abstract Scope A hypereutectic Al-Si-Cu alloy was designed and evaluated for high strength and elevated temperature automotive applications using laser powder bed fusion (LPBF). A computational design approach combined with meltspinning experiments enabled rapid alloy development and down selection for atomization. Parameter development for the Al-Si-Cu alloy revealed a large printability range, between 1-3 J/mm2, with consolidation greater than 99.97% density. Electron backscatter diffraction (EBSD) analysis revealed an isotropic microstructure with no texturing, and transmission electron microscopy (TEM) revealed nano-Si particle formation and Al2Cu Theta-phase precipitation. Elevated uniaxial tensile properties and fully reversed (R=-1) tension-compression high cycle fatigue (1e7) show superior strengths compared to the commercial AlSi10Mg alloy across all test temperatures up to 300C.
Proceedings Inclusion? Planned:
Keywords Additive Manufacturing, Aluminum, Mechanical Properties

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

A-54: Enhanced Mechanical Properties of Functional Grade Materials Fabricated from 316L Stainless Steel and Fe-based Medium Entropy Alloy Using Direct Energy Deposition Process
A-55: Optimization of Directed Energy Deposition Processed Inconel 625 Alloy via Response Surface Methodology
A-56: Synchrotron X-ray Imaging of the Effect of TiB2 Additions on Laser Powder Bed Fusion (LPBF) of Al-2139
A Calibration-Free Physics-based Framework to Predict Printability Maps in Additive Manufacturing Process
A Powder-free Methodology to Develop New High-strength Al-alloys with Unique Microstructures and Mechanical Properties
Additive Manufacturing of Highly-reinforced Metal Matrix Composites
Additive Manufacturing of Inconel 718 by Meltpool and Grain Boundary Engineering
Additively Manufactured β-Ti5553 with Laser Powder Bed Fusion: Microstructures and Mechanical Properties of Bulk and Lattice Parts
Al-Ce Alloys for Additive Manufacturing
Algorithmic Design of Functionally Graded Alloys
Capturing the Effect of a Novel Inoculant on the Microstructure and Mechanical Properties in a Stainless Steel 316L Alloy Produced by Laser Powder Bed Fusion
Comparing Microstructure and Tensile Properties of Wrought and LP-DED Haynes 233: Effects of Heat Treatment and Test Temperature
Design and Development of New Metastable Titanium Alloys for Use in Laser Powder Bed Fusion
Design of a TRIP and TWIP Steel through Additive Manufacturing of Dissimilar Steels
Design of an Aluminum Alloy Based on Stable Nanoparticles for Eliminating Process Instability in Laser Metal Additive Manufacturing
Development of a Gamma-prime-strengthened Ni-base Superalloy for Laser Powder Bed Fusion
Development of a High Throughput Method to Assess the Suitability of New Metals for Additive Manufacturing
Development of a Methodology for AM-compatible Rapid Alloy Development
Development of Low-Mn added Fe Based Lightweight Steel via Direct Energy Deposition
Directed-energy Deposition of Ti-6Al-4V Alloy Using Fresh and Recycled Feedstock Powders under Reactive Atmosphere
Directed Energy Deposition (DED) of Ni-Al Functionally Integrated Materials (FIMs) via In-situ Alloying with Elemental Ni and Al Powder Feedstocks
Effect of Carbon Content on the Microstructure and Mechanical Properties of Steels Additively Manufactured by Laser Powder Bed Fusion
Effect of Stress Relief Temperature on Microstructure and Mechanical Behavior of Additively Manufactured Ti-5Al-5Mo-5V-1Cr-1Fe
Effects of Oxygen Exposure and Powder Chemistry on Oxide Dispersion Strengthened Steels Printed with Gas Atomization Reaction Synthesis (GARS) Powders
Evaluation of SLM Parameters for Producing Elementally Homogeneous Printed Products Using Novel Dry Metal Alloy (DMA) Powder Feedstock
Expansion of Additive Manufacturing Capabilities into In-situ Alloying of Dispersion Strengthened, High Temperature Cu Alloys
Finding “Printing” Alloys: A New Category of Aluminum(-Cerium) Alloys in an Untapped Composition Space
Fine-tuning Hierarchy: Targeted In-situ Annealing of Additively Manufactured Titanium Lattices
Grain Boundary Engineering of New Additive Manufactured Polycrystalline Alloys
Grain Refinement in Fusion Based Additive Manufacturing
Hypereutectic Al-Si-Cu Alloy for Laser Powder Bed Fusion
ICME-guided Design of Ni-based Superalloy Coatings for High-temperature Industrial Applications
Impact of Starting Particle Content and Laser Powder Bed Fusion Processing on Microstructure and Material Properties in A6061-RAM Alloys
In-Situ Alloying As An Approach for Alloy Development: Does It Work?
In-situ Reactive Printing of Aluminum Matrix Composite with Ultra-high Volume Fraction Reinforcement
Investigation of Cracking in GRCop42-Inconel 625 Joints
Laser Powder Bed Fusion of Al-Ce Alloys
Laser Powder Bed Fusion of Defect-Free NiTi Shape Memory Alloy Parts with Superior Mechanical Response
Laser Powder Bed Fusion of Nanoparticles-Enabled High-Zinc Al-Zn-Mg-Cu Alloys
Laser Powder Bed Fusion Processing of Mechanically Alloyed 4wt% TiC Nanoparticle Reinforced 316L Stainless Steel
Manufacturing of MS1-P20 Hybrid Steels via Laser Powder Bed Fusion
Microstructural Engineering of Metastable Ti-Al-V-Fe Alloy via In Situ Alloying during Laser Powder Bed Fusion
Microstructure and High-temperature Mechanical Properties of a Novel Al-Ni-Fe-Zr Alloy Processed by Laser Powder Bed Fusion
Microstructure and Mechanical Properties of Al-5Mg2Si-2Mg Alloy Processed by Laser Powder Bed Fusion
Microstructure and Mechanical Properties of Arc Melted NiSi11Cx Alloys
Microstructure and Mechanical Properties of In-situ Nano Oxide Reinforced CrMnFeCoNi High Entropy Alloy Matrix Composite Manufactured by Laser Powder Bed Fusion
Microstructure and Mechanical Properties of Near-eutectic Al-Ce-Ni-Fe Alloys Produced by Laser Powder-bed Fusion
New Feedstock Design for Additive Manufacturing Using a Commercial Alloy Powder Mixture
Operando X-ray Diffraction Reveals Solidification Pathway of High Entropy Alloys with Different Degrees of Metastability
Oxide Coarsening Effects during Melt-based Additive Manufacturing -- Physics-based Modeling
Oxide Coarsening Effects during Melt-based Additive Manufacturing: Experiment and Characterization
Peculiarities of Structure Formation in Aluminum Alloys Alloyed with Transition Metals during Laser Powder Bed Fusion
Physics-constrained, Inverse Design of High-temperature, High-strength, Creep-resistant Printable Al Alloys Using Machine Learning Methods
Selective Phase Transformation Behavior in the Heterogeneous Microstructured Ti-Zr-Nb-Sn Alloy Manufactured by Directed Energy Deposition
Suppressing Large Columnar Grain Structures in Ti Alloys Processed with Laser Wire Directed Energy Deposition
The Development of a Directed Energy Deposition (DED) Printability Framework for Improving Part Density and Performance in High Strength Martensitic Steels
Ultra-High Strength and Ductility in a Lightweight Fe-Mn-Al-C Austenitic Steel Fabricated via Laser Powder Bed Fusion
Understanding the Influence of Boron in Additively Manufactured CoNi-based Superalloys Using Atom Probe Tomography
Unique Microstructure and Phase Transformation Pathway in an Additively Manufactured 316L-ceramic Composite
Using θ' Interfaces as Templates for Planar L12 Precipitation in Additively Manufactured AlCuMnZr Alloys
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