Selective Laser Melted High Mg‐Content Al–Si–Mg–Zr Aluminum Alloy with the Formation of Stacking Faults

The currently applied selective laser melted (SLMed) Al–Si–Mg aluminum alloys generally exhibit low strength. Increasing the Mg content is an effective method to enhance the strength of those alloys. However, an excessive Mg content reduces their processability and plasticity. Herein, Zr is chosen as the alloying element to enhance the processability and plasticity of the SLMed high Mg‐content Al–Si–Mg alloy. The results demonstrate that the alloying of the Zr element is beneficial for improving the alloy's processability and mechanical properties through grain refinement. Besides, the high‐concentration solid solution of low‐stacking fault energy (SFE) elements, including Mn, Zr, and Mg, effectively reduces the SFE of the alloy, thereby promoting the formation of stacking faults. The yield strength, ultimate tensile strength, and elongation of the alloy are 388 ± 3, 503 ± 6 MPa, and 5.1 ± 1%, respectively. The strength of the present alloy is higher than that of previously reported SLMed Al–Si–Mg aluminum alloys.