In recent years, additive manufacturing (AP) has become a revolutionary method for creating complex metal components, opening up new horizons in materials science and engineering. However, the use of AP for the production of quasicrystalline alloys (QCS) with unique combinations of properties remains a challenging task. This paper presents an integrated approach to the development and production of aluminum – based CCS – Al95Fe2Cr2Ti1-by selective laser melting (SLM). The focus is on achieving outstanding heat resistance and ductility, critical for aerospace and automotive applications.
Initial research focuses on optimizing SLM parameters, including laser power, scanning speed, and track spacing. The goal is to achieve a dense microstructure, minimize cracks, and preserve the quasicrystalline phase during rapid solidification. To achieve an optimal balance between these factors, the Experiment Planning Method (DOE) was used.
In this paper, we study the phase formation process, resistance to high temperatures, and mechanical characteristics of a metastable quasicrystalline AlFe2Cr2Ti1 alloy produced using selective laser melting (SLP) technology. The initial powder for SLP was obtained by gas spraying using recycled raw materials (aluminum containers), which provides economic benefits and benefits for society. It is established that its composition, particle size, flowability and shape meetthe requirements of the SLP process.
The samples were prepared by the SLP method in various orientations (0°, 45°, and 90°) and achieved a high relative density of 99.3-99.8 %. SLP treatment of Al95Fe2Cr2Ti1 powder resulted in the formation of a structure with nanoscale quasicrystalline inclusions in the dendritic α-Al matrix, mainly in the central part of the melting zone. Larger but also nanoscale quasicrystalline and crystalline phases were observed in the zones of thermal influence.
Similar phase transformations and hardness (180.33 HV) were observed in both parts of the samples, regardless of the construction direction. Due to the formation of ultrafine precipitates and grain grinding, the samples demonstrated high compressive strength both at room temperature and at 400 °C. The resulting material showed an impressive yield strength (140 ± 13 MPa) and increased compressive ductility at 400 °C, surpassing the performance of SLP-derived AlSi alloys and traditional high-temperature Al alloys. These results open up prospects for creating high-performance heat-resistant alloys that form quasicrystals, with the possibility of producing parts of complex geometry and reducing the cost of production.
Further analysis of the obtained samples revealed a significant impact of post-processing, particularly hot isostatic pressing (HIP), on the mechanical properties of the alloy. HIP significantly improves the density of the material, reduces the concentration of residual stresses, and has a positive effect on the grain boundary structure. This leads to an increase in both the tensile strength and the elongation at break at elevated temperatures, confirming the improved heat resistance and ductility of the final product.
The obtained results demonstrate the potential of additive manufacturing for creating CCS with improved properties. This approach opens up new opportunities for the development of high-performance materials for various industries that require a combination of high strength, lightness, and resistance to high temperatures.
Author: Aylanna P.M. de Araujo, Simon Pauly, Rodolfo L. Batalha, Francisco G. Coury, Claudio S. Kiminami, Volker Uhlenwinkel, Piter Gargarella
Intitute: Graduate Program in Materials Science and Engineering, Federal University of São Carlos, Rod. Washington Luis Km 235, 13565-905, São Carlos, Brazil, Faculty of Engineering, University of Applied Sciences Aschaffenburg, Würzburger Str. 45, D-63743 Aschaffenburg, Germany, Institute for Complex Materials, Leibniz Institute for Solid State and Materials Research, Helmholtzstraße 20, D-01069 Dresden, Germany, Department of Materials Engineering (DEMa), Federal University of São Carlos (UFSCar), Rod. Washington Luis Km 235, 13565-905, São Carlos, Brazil, Leibniz-Institut für Werkstofforientierte Technologien – IWT Bremen, Badgasteinerstr. 3, 28359 Bremen, Germany