Additively manufactured fine-grained ultrahigh-strength bulk aluminum alloys with nanostructured strengthening defects

Gan Li; Chunlu Zhao; Yuhe Huang; Qiyang Tan; Junhua Hou; Xi He; Chuan Guo; Wenjun Lu; Lin Zhou; Sida Liu; Lei Zhang; Xuliang Chen; Xinggang Li; Ying Li; Junhua Luan; Zhenmin Li; Xinping Mao; Ming-Xing Zhang; Qiang Zhu; Jian Lu

doi:10.1016/j.mattod.2024.05.006

Additively manufactured fine-grained ultrahigh-strength bulk aluminum alloys with nanostructured strengthening defects

Gan Li (Co-first Author), Chunlu Zhao (Co-first Author), Yuhe Huang^*, Qiyang Tan, Junhua Hou, Xi He, Chuan Guo, Wenjun Lu, Lin Zhou, Sida Liu, Lei Zhang, Xuliang Chen, Xinggang Li, Ying Li, Junhua Luan, Zhenmin Li, Xinping Mao, Ming-Xing Zhang^*, Qiang Zhu^*, Jian Lu^*

^*Corresponding author for this work

Research output: Journal Publications and Reviews › RGC 21 - Publication in refereed journal › peer-review

38 Citations (Scopus)

Abstract

In response to the critical need for lightweight designs and carbon neutrality, we introduce an innovative additively manufactured ultrafine-grained Al-Mg-Mn-Sc-Zr alloy reinforced with nano-structured planar defects via laser powder bed fusion (L-PBF), developed for complex-shaped parts that demand high strength and superior ductility. Owing to the uneven distribution of the L1₂-ordered Al₃(Sc, Zr) nanoparticles, the as-printed alloy demonstrates a hierarchically heterogeneous microstructure featuring a triple-modal grain distribution. Tailored planar defects comprising stacking faults, 9R phase and nanotwins are strategically introduced in the as-printed alloy. Beyond the nano-scaled planar defects and the triple-modal grain distribution, further direct ageing process augments the abundance of nanoprecipitates, collectively boosting the yield strength to 656 MPa, which is higher than almost all L-PBFed Al alloys hitherto reported, and a decent ductility of 7.2 %. This work paves the way for the near net shape forming of high-performance Al alloy components for advanced structural applications. © 2024 Elsevier Ltd.

Original language	English
Pages (from-to)	40-51
Journal	Materials Today
Volume	76
Online published	8 Jun 2024
DOIs	https://doi.org/10.1016/j.mattod.2024.05.006
Publication status	Published - Jul 2024

Funding

This work was supported by the National Natural Science Foundation of China [grant number 52074157 , N_CityU151/23]; the Guangdong Basic and Applied Basic Research Foundation [grant number 2021A1515110348 ]; the China Postdoctoral Science Foundation [grant number 2023M730228 ]; the Australian Research Council [grant number DP210103162 ]; the Special Funds for the Cultivation of Guangdong College Students’ Scientific and Technological Innovation (No. pdjh2024c10809 ); and the Shenzhen Science and Technology Project [grant numbers JCYJ20220818100613028 , JCYJ20210324104610029 , JCYJ20210324104608023 , ZDSYS201703031748354 ]. APT research was conducted at the Inter-University 3D APT Unit of City University of Hong Kong (CityU), which is supported by the CityU grant 9360161. G.L. thanks the SUSTech-CityU collaborative PhD programme for the support.

Research Keywords

Additive manufacturing
Aluminum alloy
Grain refinement
Laser powder bed fusion
Planar defects
Ultrahigh strength

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1016/j.mattod.2024.05.006

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Li, G., Zhao, C., Huang, Y., Tan, Q., Hou, J., He, X., Guo, C., Lu, W., Zhou, L., Liu, S., Zhang, L., Chen, X., Li, X., Li, Y., Luan, J., Li, Z., Mao, X., Zhang, M.-X., Zhu, Q., & Lu, J. (2024). Additively manufactured fine-grained ultrahigh-strength bulk aluminum alloys with nanostructured strengthening defects. Materials Today, 76, 40-51. https://doi.org/10.1016/j.mattod.2024.05.006

@article{da223d6a1bd54b508a09cb973e47a553,

title = "Additively manufactured fine-grained ultrahigh-strength bulk aluminum alloys with nanostructured strengthening defects",

abstract = "In response to the critical need for lightweight designs and carbon neutrality, we introduce an innovative additively manufactured ultrafine-grained Al-Mg-Mn-Sc-Zr alloy reinforced with nano-structured planar defects via laser powder bed fusion (L-PBF), developed for complex-shaped parts that demand high strength and superior ductility. Owing to the uneven distribution of the L12-ordered Al3(Sc, Zr) nanoparticles, the as-printed alloy demonstrates a hierarchically heterogeneous microstructure featuring a triple-modal grain distribution. Tailored planar defects comprising stacking faults, 9R phase and nanotwins are strategically introduced in the as-printed alloy. Beyond the nano-scaled planar defects and the triple-modal grain distribution, further direct ageing process augments the abundance of nanoprecipitates, collectively boosting the yield strength to 656 MPa, which is higher than almost all L-PBFed Al alloys hitherto reported, and a decent ductility of 7.2 %. This work paves the way for the near net shape forming of high-performance Al alloy components for advanced structural applications. {\textcopyright} 2024 Elsevier Ltd.",

keywords = "Additive manufacturing, Aluminum alloy, Grain refinement, Laser powder bed fusion, Planar defects, Ultrahigh strength",

author = "Gan Li and Chunlu Zhao and Yuhe Huang and Qiyang Tan and Junhua Hou and Xi He and Chuan Guo and Wenjun Lu and Lin Zhou and Sida Liu and Lei Zhang and Xuliang Chen and Xinggang Li and Ying Li and Junhua Luan and Zhenmin Li and Xinping Mao and Ming-Xing Zhang and Qiang Zhu and Jian Lu",

year = "2024",

month = jul,

doi = "10.1016/j.mattod.2024.05.006",

language = "English",

volume = "76",

pages = "40--51",

journal = "Materials Today",

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Li, G, Zhao, C, Huang, Y, Tan, Q, Hou, J, He, X, Guo, C, Lu, W, Zhou, L, Liu, S, Zhang, L, Chen, X, Li, X, Li, Y, Luan, J, Li, Z, Mao, X, Zhang, M-X, Zhu, Q & Lu, J 2024, 'Additively manufactured fine-grained ultrahigh-strength bulk aluminum alloys with nanostructured strengthening defects', Materials Today, vol. 76, pp. 40-51. https://doi.org/10.1016/j.mattod.2024.05.006

TY - JOUR

T1 - Additively manufactured fine-grained ultrahigh-strength bulk aluminum alloys with nanostructured strengthening defects

AU - Li, Gan

AU - Zhao, Chunlu

AU - Huang, Yuhe

AU - Tan, Qiyang

AU - Hou, Junhua

AU - He, Xi

AU - Guo, Chuan

AU - Lu, Wenjun

AU - Zhou, Lin

AU - Liu, Sida

AU - Zhang, Lei

AU - Chen, Xuliang

AU - Li, Xinggang

AU - Li, Ying

AU - Luan, Junhua

AU - Li, Zhenmin

AU - Mao, Xinping

AU - Zhang, Ming-Xing

AU - Zhu, Qiang

AU - Lu, Jian

PY - 2024/7

Y1 - 2024/7

N2 - In response to the critical need for lightweight designs and carbon neutrality, we introduce an innovative additively manufactured ultrafine-grained Al-Mg-Mn-Sc-Zr alloy reinforced with nano-structured planar defects via laser powder bed fusion (L-PBF), developed for complex-shaped parts that demand high strength and superior ductility. Owing to the uneven distribution of the L12-ordered Al3(Sc, Zr) nanoparticles, the as-printed alloy demonstrates a hierarchically heterogeneous microstructure featuring a triple-modal grain distribution. Tailored planar defects comprising stacking faults, 9R phase and nanotwins are strategically introduced in the as-printed alloy. Beyond the nano-scaled planar defects and the triple-modal grain distribution, further direct ageing process augments the abundance of nanoprecipitates, collectively boosting the yield strength to 656 MPa, which is higher than almost all L-PBFed Al alloys hitherto reported, and a decent ductility of 7.2 %. This work paves the way for the near net shape forming of high-performance Al alloy components for advanced structural applications. © 2024 Elsevier Ltd.

AB - In response to the critical need for lightweight designs and carbon neutrality, we introduce an innovative additively manufactured ultrafine-grained Al-Mg-Mn-Sc-Zr alloy reinforced with nano-structured planar defects via laser powder bed fusion (L-PBF), developed for complex-shaped parts that demand high strength and superior ductility. Owing to the uneven distribution of the L12-ordered Al3(Sc, Zr) nanoparticles, the as-printed alloy demonstrates a hierarchically heterogeneous microstructure featuring a triple-modal grain distribution. Tailored planar defects comprising stacking faults, 9R phase and nanotwins are strategically introduced in the as-printed alloy. Beyond the nano-scaled planar defects and the triple-modal grain distribution, further direct ageing process augments the abundance of nanoprecipitates, collectively boosting the yield strength to 656 MPa, which is higher than almost all L-PBFed Al alloys hitherto reported, and a decent ductility of 7.2 %. This work paves the way for the near net shape forming of high-performance Al alloy components for advanced structural applications. © 2024 Elsevier Ltd.

KW - Additive manufacturing

KW - Aluminum alloy

KW - Grain refinement

KW - Laser powder bed fusion

KW - Planar defects

KW - Ultrahigh strength

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UR - https://www.scopus.com/record/pubmetrics.uri?eid=2-s2.0-85195292776&origin=recordpage

U2 - 10.1016/j.mattod.2024.05.006

DO - 10.1016/j.mattod.2024.05.006

M3 - RGC 21 - Publication in refereed journal

SN - 1369-7021

VL - 76

SP - 40

EP - 51

JO - Materials Today

JF - Materials Today

ER -

Additively manufactured fine-grained ultrahigh-strength bulk aluminum alloys with nanostructured strengthening defects

Abstract

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Research Keywords

UN SDGs

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NSFC: Bulk Complex Concentrated Alloys Based on Grain Boundary Complexion Engineering and Study of Their Toughening Mechanisms

ResFac: Inter-University 3D Atom Probe Tomography Unit

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Additively manufactured fine-grained ultrahigh-strength bulk aluminum alloys with nanostructured strengthening defects

Abstract

Funding

Research Keywords

UN SDGs

Access Output

Other Access Options

Permanent Link

Other Files and Links

Fingerprint

Projects

NSFC: Bulk Complex Concentrated Alloys Based on Grain Boundary Complexion Engineering and Study of Their Toughening Mechanisms

ResFac: Inter-University 3D Atom Probe Tomography Unit

Cite this