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*

*Corresponding author for this work

Research output: Journal Publications and ReviewsRGC 21 - Publication in refereed journalpeer-review

32 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 languageEnglish
Pages (from-to)40-51
JournalMaterials Today
Volume76
Online published8 Jun 2024
DOIs
Publication statusPublished - 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

Fingerprint

Dive into the research topics of 'Additively manufactured fine-grained ultrahigh-strength bulk aluminum alloys with nanostructured strengthening defects'. Together they form a unique fingerprint.

Cite this