Effect of Heat Treatment on Gradient Microstructure of AlSi10Mg Lattice Structure Manufactured by Laser Powder Bed Fusion

Recycled aluminium feedstock in metal additive manufacturing: A state of the art review

Additive manufacturing has revolutionised the production of functional components and assemblies, offering a high degree of manufacturing flexibility. This review explores the latest advancements in additive manufacturing, focusing on its fusion-based and solid-state based technologies, and highlights the use of recycled aluminium as feedstock in these processes. The advantages and limitations of incorporating recycled materials are thoroughly analysed, considering factors such as material properties, sustainability, and process acceptance. While up to 14.4 kg CO2 per kg of aluminium is released during primary aluminium ingot production, solid-state based additive manufacturing, which is tolerant of feedstock contamination, can directly recycle aluminium. Meanwhile, fusion based additive manufacturing can readily utilise recycling pathways such as maintaining grade, upcycling, and downcycling, as well as powder reuse, providing opportunities for significant emissions reduction. The examination of feedstock manufacturing in this review, such as wire for WAAM and powder for PBF, indicates that this step indirectly increases the resource consumption of additive manufacturing. Finally, the alignment of aluminium recycling and additive manufacturing with Circular Economy principles and the UN's sustainable development goals are addressed, highlighting contributions to SDGs 3, 9, and 12.

The efficiency of tumble finishing as a final post-treatment for fatigue enhancement of notched laser powder bed fusion AlSi10Mg

A hybrid post-treatment combining tumble finishing as a final step after shot peening and heat treatment was developed to alleviate the adverse effects of internal and surface defects on the fatigue performance of laser powder bed fusion AlSi10Mg samples. The effects of each post-treatment were investigated individually and synergistically on microstructure, surface morphology and roughness, hardness, residual stresses, porosity, and rotating bending fatigue behavior of V-notched AlSi10Mg samples. The results reveal that tumble finishing can highly reduce surface roughness by 28 and 32% compared to the as-built and heat-treated states while inducing extra surface layer hardening and compressive residual stresses. The hybrid post-treatment of heat treatment + shot peening + tumble finishing significantly increased the fatigue life of the samples by over 500 times higher compared to the as-built series.

Additive Manufacturing of AlSi10Mg and Ti6Al4V Lightweight Alloys via Laser Powder Bed Fusion: A Review of Heat Treatments Effects

Laser powder bed fusion (L-PBF) is an additive manufacturing technology that is gaining increasing interest in aerospace, automotive and biomedical applications due to the possibility of processing lightweight alloys such as AlSi10Mg and Ti6Al4V. Both these alloys have microstructures and mechanical properties that are strictly related to the type of heat treatment applied after the L-PBF process. The present review aimed to summarize the state of the art in terms of the microstructural morphology and consequent mechanical performance of these materials after different heat treatments. While optimization of the post-process heat treatment is key to obtaining excellent mechanical properties, the first requirement is to manufacture high quality and fully dense samples. Therefore, effects induced by the L-PBF process parameters and build platform temperatures were also summarized. In addition, effects induced by stress relief, annealing, solution, artificial and direct aging, hot isostatic pressing, and mixed heat treatments were reviewed for AlSi10Mg and Ti6AlV samples, highlighting variations in microstructure and corrosion resistance and consequent fracture mechanisms.

Passive Film Properties of Bimodal Grain Size AA7075 Aluminium Alloy Prepared by Spark Plasma Sintering

The bimodal-grain-size 7075 aluminium alloys containing varied ratios of large and small 7075 aluminium powders were prepared by spark plasma sintering (SPS). The large powder was 100 ± 15 μm in diameter and the small one was 10 ± 5 μm in diameter. The 7075 aluminium alloys was completely densified under the 500 °C sintering temperature and 60 MPa pressure. The large powders constituted coarse grain zone, and the small powders constituted fine grain zone in sintered 7075 aluminium alloys. The microstructural and microchemical difference between the large and small powders was remained in coarse and fine grain zones in bulk alloys after SPS sintering, which allowed for us to investigate the effects of microstructure and microchemistry on passive properties of oxide film formed on sintered alloys. The average diameter of intermetallic phases was 201.3 nm in coarse grain zone, while its vale was 79.8 nm in fine grain zone. The alloying element content in intermetallic phases in coarse grain zone was 33% to 48% higher than that on fine grain zone. The alloying element depletion zone surrounding intermetallic phases in coarse grain zone showed a bigger width and a more severe element depletion. The coarse grain zone in alloys showed a bigger electrochemical heterogeneity as compared to fine grain zone. The passive film formed on coarse grain zone had a thicker thickness and a point defect density of 2.4 × 10²⁴ m⁻³, and the film on fine grain zone had a thinner thickness and a point defect density of 4.0 × 10²³ m⁻³. The film resistance was 3.25 × 10⁵ Ωcm² on coarse grain zone, while it was 6.46 × 10⁵ Ωcm² on fine grain zone. The passive potential range of sintered alloys increased from 457 mV to 678 mV, while the corrosion current density decreased from 8.59 × 10⁻⁷ A/cm² to 6.78 × 10⁻⁷ A/cm² as fine grain zone increasing from 0% to 100%, which implied that the corrosion resistance of alloys increased with the increasing content of fine grains. The passive film on coarse grain zone exhibited bigger corrosion cavities after pitting initiation compared to that on fine grain zone. The passive film formed on fine grain zone showed a better corrosion resistance. The protectiveness of passive film was mainly determined by defect density rather than the thickness in this work.

Compressive Properties of Al-Si Alloy Lattice Structures with Three Different Unit Cells Fabricated via Laser Powder Bed Fusion

In the present study, in order to elucidate geometrical features dominating deformation behaviors and their associated compressive properties of lattice structures, AlSi10Mg lattice structures with three different unit cells were fabricated by laser powder bed fusion. Compressive properties were examined by compression and indentation tests, micro X-ray computed tomography (CT), together with finite element analysis. The truncated octahedron- unit cell (TO) lattice structures exhibited highest stiffness and plateau stress among the studied lattice structures. The body centered cubic-unit cell (BCC) and TO lattice structures experienced the formation of shear bands with stress drops, while the hexagon-unit cell (Hexa) lattice structure behaved in a continuous deformation and flat plateau region. The Hexa lattice structure densified at a smaller strain than the BCC and TO lattice structures, due to high density of the struts in the compressive direction. Static and high-speed indentation tests revealed that the TO and Hexa exhibited slight strain rate dependence of the compressive strength, whereas the BCC lattice structure showed a large strain rate dependence. Among the lattice structures in the present study, the TO lattice exhibited the highest energy absorption capacity comparable to previously reported titanium alloy lattice structures.