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Additive manufacturing of an ultrastrong, deformable Al alloy with nanoscale intermetallics

Author

Listed:
  • Anyu Shang

    (Purdue University)

  • Benjamin Stegman

    (Purdue University)

  • Kenyi Choy

    (University of Illinois Urbana-Champaign)

  • Tongjun Niu

    (Purdue University
    Los Alamos National Lab)

  • Chao Shen

    (Purdue University)

  • Zhongxia Shang

    (Purdue University)

  • Xuanyu Sheng

    (Purdue University)

  • Jack Lopez

    (Purdue University)

  • Luke Hoppenrath

    (Purdue University)

  • Bohua Peter Zhang

    (Purdue University)

  • Haiyan Wang

    (Purdue University)

  • Pascal Bellon

    (University of Illinois Urbana-Champaign)

  • Xinghang Zhang

    (Purdue University)

Abstract

Light-weight, high-strength, aluminum (Al) alloys have widespread industrial applications. However, most commercially available high-strength Al alloys, like AA 7075, are not suitable for additive manufacturing due to their high susceptibility to solidification cracking. In this work, a custom Al alloy Al92Ti2Fe2Co2Ni2 is fabricated by selective laser melting. Heterogeneous nanoscale medium-entropy intermetallic lamella form in the as-printed Al alloy. Macroscale compression tests reveal a combination of high strength, over 700 MPa, and prominent plastic deformability. Micropillar compression tests display significant back stress in all regions, and certain regions have flow stresses exceeding 900 MPa. Post-deformation analyses reveal that, in addition to abundant dislocation activities in Al matrix, complex dislocation structures and stacking faults form in monoclinic Al9Co2 type brittle intermetallics. This study shows that proper introduction of heterogeneous microstructures and nanoscale medium entropy intermetallics offer an alternative solution to the design of ultrastrong, deformable Al alloys via additive manufacturing.

Suggested Citation

  • Anyu Shang & Benjamin Stegman & Kenyi Choy & Tongjun Niu & Chao Shen & Zhongxia Shang & Xuanyu Sheng & Jack Lopez & Luke Hoppenrath & Bohua Peter Zhang & Haiyan Wang & Pascal Bellon & Xinghang Zhang, 2024. "Additive manufacturing of an ultrastrong, deformable Al alloy with nanoscale intermetallics," Nature Communications, Nature, vol. 15(1), pages 1-12, December.
    • Handle: RePEc:nat:natcom:v:15:y:2024:i:1:d:10.1038_s41467-024-48693-4
    DOI: 10.1038/s41467-024-48693-4
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    References listed on IDEAS

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    1. John H. Martin & Brennan D. Yahata & Jacob M. Hundley & Justin A. Mayer & Tobias A. Schaedler & Tresa M. Pollock, 2017. "3D printing of high-strength aluminium alloys," Nature, Nature, vol. 549(7672), pages 365-369, September.
    2. Ting-Chiang Lin & Chezheng Cao & Maximilian Sokoluk & Lin Jiang & Xin Wang & Julie M. Schoenung & Enrique J. Lavernia & Xiaochun Li, 2019. "Aluminum with dispersed nanoparticles by laser additive manufacturing," Nature Communications, Nature, vol. 10(1), pages 1-9, December.
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