Characterisation of a High-Performance Al-Zn-Mg-Cu Alloy Designed for Wire Arc Additive Manufacturing

Ever-increasing demands of industrial manufacturing regarding mechanical properties require the development of novel alloys designed towards the respective manufacturing process. Here, we consider wire arc additive manufacturing. To this end, Al alloys with additions of Zn, Mg and Cu have been designed considering the requirements of good mechanical properties and limited hot cracking susceptibility. The samples were produced using the cold metal transfer pulse advanced (CMT-PADV) technique, known for its ability to produce lower porosity parts with smaller grain size. After material simulations to determine the optimal heat treatment, the samples were solution heat treated, quenched and aged to enhance their mechanical performance. Chemical analysis, mechanical properties and microstructure evolution were evaluated using optical light microscopy, scanning electron microscopy, energy dispersive X-ray spectroscopy, X-ray fluorescence analysis and X-ray radiography, as well as tensile, fatigue and hardness tests. The objective of this research was to evaluate in detail the mechanical properties and microstructure of the newly designed high-performance Al–Zn-based alloy before and after ageing heat treatment. The only defects found in the parts built under optimised conditions were small dispersed porosities, without any visible cracks or lack of fusion. Furthermore, the mechanical properties are superior to those of commercial 7xxx alloys and remarkably independent of the testing direction (parallel or perpendicular to the deposit beads). The presented analyses are very promising regarding additive manufacturing of high-strength aluminium alloys.

Efficient pump beam shaping for high-power thin-disk laser systems

We report a beam-shaping technique whereby the output power from a high-power laser-diode stack is efficiently coupled, reconfigured, and transmitted to a thin-disk laser by means of a compact optical fiber bundle. By using this technique, the power density is increased by a factor of 2 when compared to direct coupling with a octagonal fused silica rod while the numerical aperture is kept constant. Transmission efficiency of 80% was measured for the beam shaper without antireflection coating. The top-hat distribution is numerically calculated at the thin-disk laser crystal.