Improvement in the PBF-LB/M processing of the Al-Si-Cu-Mg composition through the use of pre-alloyed powder

Abstract Among the many additive manufacturing technologies for metals, Powder Bed Fusion-Laser Beam (PBF-LB\M) stands out for its capacity to produce complex-shaped functional parts. However, the PBF-LB\M materials portfolio is still limited and the research into new high-performance Al-based alloys is ongoing. The improved properties with the addition of 4 wt% Cu to the AlSi10Mg alloy have been previously investigated in the literature through the in situ alloying approach in which the starting powders of Cu and AlSi10Mg are mechanically mixed and directly processed. However, inhomogeneities of alloying elements were found in samples produced with mixed AlSi10Mg+4Cu powders. To overcome this detrimental problem, the use of pre-alloyed AlSI10Cu4Mg powder obtained via gas atomisation process could be a powerful solution. With the aim of demonstrating the beneficial effects of pre-alloyed AlSi10Cu4Mg powders in laser-powder interaction, preliminary SEM investigations were conducted on cross-sectioned SSTs and bulk samples after optimising the process parameters. The deeper microstructural investigations conducted on pre-alloyed AlSi10Cu4Mg samples revealed a higher homogeneity of alloying elements, a smaller cell size of the Al-Si-Cu network (0.5 versus 0.8 μm) and a slightly smaller mean diameter of equiaxial grains compared to the mixed AlSi10Mg+4Cu ones (6.01 versus 7.34 μm). In addition, looking closer at the supersaturation level and the precipitation behaviour in pre-alloyed AlSi10Cu4Mg composition, a high solid solution level, a massive presence of Al₂Cu in the cell network and only a few finely dispersed Al₂Cu precipitates within the cells were found. Exploring the benefits of these microstructural features on mechanical properties, an increase in performance of about 18% in micro-hardness tests and more than 10% in tensile and compressive tests were found in the AlSi10Cu4Mg system with respect to the mixed AlSi10Mg+4Cu system. All the thorough investigations proved how using pre-alloyed powders is an important advantage in the PBF-LB/M production of complex Al-based systems.