Correlation between Differential Fast Scanning Calorimetry and Additive Manufacturing Results of Aluminium Alloys.

High-strength aluminium alloy powders modified with different nanoparticles by ball milling (7075/TiC, 2024/CaB6, 6061/YSZ) have been investigated in-situ during rapid solidification by differential fast scanning calorimetry (DFSC). Solidification undercooling has been evaluated and was found to decrease with an increasing number of nanoparticles, as the particles act as nuclei for solidification. Lower solidification undercooling of individual powder particles correlates with less hot cracking and smaller grains in the material produced by powder bed fusion of metals by a laser beam (PBF-LB/M).

Requirements for Processing High-Strength AlZnMgCu Alloys with PBF-LB/M to Achieve Crack-Free and Dense Parts.

Processing aluminum alloys employing powder bed fusion of metals (PBF-LB/M) is becoming more attractive for the industry, especially if lightweight applications are needed. Unfortunately, high-strength aluminum alloys such as AA7075 are prone to hot cracking during PBF-LB/M, as well as welding. Both a large solidification range promoted by the alloying elements zinc and copper and a high thermal gradient accompanied with the manufacturing process conditions lead to or favor hot cracking.