US20190291182A1 - Aluminum alloy powders for powder bed fusion additive manufacturing processes - Google Patents
Aluminum alloy powders for powder bed fusion additive manufacturing processes Download PDFInfo
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- US20190291182A1 US20190291182A1 US15/934,342 US201815934342A US2019291182A1 US 20190291182 A1 US20190291182 A1 US 20190291182A1 US 201815934342 A US201815934342 A US 201815934342A US 2019291182 A1 US2019291182 A1 US 2019291182A1
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- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 205
- 239000000843 powder Substances 0.000 title claims abstract description 66
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 27
- 239000000654 additive Substances 0.000 title claims description 14
- 230000000996 additive effect Effects 0.000 title claims description 14
- 230000004927 fusion Effects 0.000 title claims description 10
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 125
- 239000000956 alloy Substances 0.000 claims abstract description 114
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- 210000001787 dendrite Anatomy 0.000 claims abstract description 37
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- 229910045601 alloy Inorganic materials 0.000 claims description 82
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 51
- 239000012071 phase Substances 0.000 claims description 48
- 239000002667 nucleating agent Substances 0.000 claims description 36
- 229910052710 silicon Inorganic materials 0.000 claims description 31
- 239000011572 manganese Substances 0.000 claims description 30
- 229910052742 iron Inorganic materials 0.000 claims description 27
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 25
- 239000010703 silicon Substances 0.000 claims description 25
- 239000010949 copper Substances 0.000 claims description 24
- 229910052748 manganese Inorganic materials 0.000 claims description 24
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- 238000010438 heat treatment Methods 0.000 claims description 20
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- 239000002244 precipitate Substances 0.000 claims description 16
- 150000001875 compounds Chemical class 0.000 claims description 15
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- 229910052792 caesium Inorganic materials 0.000 claims description 11
- 229910052750 molybdenum Inorganic materials 0.000 claims description 11
- 229910052758 niobium Inorganic materials 0.000 claims description 11
- 229910052717 sulfur Inorganic materials 0.000 claims description 11
- 229910052715 tantalum Inorganic materials 0.000 claims description 11
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- 229910052790 beryllium Inorganic materials 0.000 claims description 10
- 229910052804 chromium Inorganic materials 0.000 claims description 10
- 229910052712 strontium Inorganic materials 0.000 claims description 10
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- 229910052721 tungsten Inorganic materials 0.000 claims description 9
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- 239000011856 silicon-based particle Substances 0.000 claims description 8
- 229910052720 vanadium Inorganic materials 0.000 claims description 8
- 229910052726 zirconium Inorganic materials 0.000 claims description 8
- 229910052745 lead Inorganic materials 0.000 claims description 7
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 5
- SIXSYDAISGFNSX-UHFFFAOYSA-N scandium atom Chemical compound [Sc] SIXSYDAISGFNSX-UHFFFAOYSA-N 0.000 claims description 4
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims description 3
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 3
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- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 claims description 3
- WATWJIUSRGPENY-UHFFFAOYSA-N antimony atom Chemical compound [Sb] WATWJIUSRGPENY-UHFFFAOYSA-N 0.000 claims description 3
- ATBAMAFKBVZNFJ-UHFFFAOYSA-N beryllium atom Chemical compound [Be] ATBAMAFKBVZNFJ-UHFFFAOYSA-N 0.000 claims description 3
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- 239000010941 cobalt Substances 0.000 claims description 3
- 229910017052 cobalt Inorganic materials 0.000 claims description 3
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 3
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 claims description 3
- 239000011733 molybdenum Substances 0.000 claims description 3
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 claims description 3
- VSZWPYCFIRKVQL-UHFFFAOYSA-N selanylidenegallium;selenium Chemical compound [Se].[Se]=[Ga].[Se]=[Ga] VSZWPYCFIRKVQL-UHFFFAOYSA-N 0.000 claims description 3
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 claims description 3
- 239000011593 sulfur Substances 0.000 claims description 3
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 claims description 3
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 3
- 239000010937 tungsten Substances 0.000 claims description 3
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 claims description 3
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 claims 2
- 229910018594 Si-Cu Inorganic materials 0.000 description 57
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Images
Classifications
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- B22F3/1055—
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
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- B22F1/0003—
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y70/00—Materials specially adapted for additive manufacturing
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/0408—Light metal alloys
- C22C1/0416—Aluminium-based alloys
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/0425—Copper-based alloys
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2301/00—Metallic composition of the powder or its coating
- B22F2301/05—Light metals
- B22F2301/052—Aluminium
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
- C22F1/043—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with silicon as the next major constituent
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- a variety of aluminum alloy compositions have been developed for use in the manufacture of three-dimensional aluminum alloy parts via casting and/or hot forming operations to impart certain desirable chemical and mechanical properties to the resulting parts.
- aluminum alloy compositions are employed as a powder feed material in a powder bed fusion additive manufacturing process, the resulting aluminum alloy parts oftentimes exhibit a columnar grain structure, and thus are relatively susceptible to cracking along grain boundaries between adjacent columnar grains. Therefore, there is a need in the art for an aluminum alloy composition that can be employed in a powder bed fusion additive manufacturing process to form three-dimensional aluminum alloy parts that predominantly exhibit an equiaxed grain structure and thus are relatively resistant or impervious to solidification cracking.
- an aluminum alloy powder for manufacturing a three-dimensional high-strength aluminum alloy part by a powder bed fusion additive manufacturing process is provided.
- Each particle of the aluminum alloy powder may comprise an aluminum alloy that includes, by weight, 13-25% silicon, 0.1-10% copper, and 0-2% magnesium.
- the aluminum alloy When the aluminum alloy is heated to a first temperature greater than a liquidus temperature of the aluminum alloy and subsequently cooled to a second temperature less than the liquidus temperature of the aluminum alloy and greater than a solidus temperature of the aluminum alloy, the aluminum alloy may transition from a liquid phase to a multiphase system.
- the multiphase system may include a solution of liquid phase aluminum and a solid phase of silicon particles dispersed throughout the liquid phase aluminum.
- the aluminum alloy may comprise, by weight, 15-22% silicon, 2-5.1% copper, and 0.6-0.8% magnesium.
- the aluminum alloy powder may comprise, by weight, 19-21% silicon, 3.5-4.1% copper, and aluminum as balance.
- the aluminum also may comprise, by weight: greater than 0% iron and less than 9% iron, and greater than 0% manganese and less than 5% manganese.
- the multiphase system may include the solution of liquid phase aluminum, the solid phase of silicon particles, and another solid phase of iron-containing intermetallic particles dispersed throughout the liquid phase aluminum.
- an aluminum alloy powder for manufacturing a three-dimensional high thermal conductivity aluminum alloy part by a powder bed fusion additive manufacturing process is provided.
- Each particle of the aluminum alloy powder may comprise an aluminum alloy that includes, by weight: greater than 95% aluminum, and greater than 0% and less than 5% of at least one nucleating agent.
- the at least one nucleating agent may comprise an element or compound having a solid solubility in aluminum of, by weight, less than 0.5% at temperatures less than 530 degrees Celsius.
- the aluminum alloy When the aluminum alloy is heated to a first temperature greater than a liquidus temperature of the aluminum alloy and subsequently cooled to a second temperature less than the liquidus temperature of the aluminum alloy and greater than a solidus temperature of the aluminum alloy, the aluminum alloy may transition from a liquid phase to a multiphase system.
- the multiphase system may include a solution of liquid phase aluminum and a solid phase of particles of the at least one nucleating agent dispersed throughout the liquid phase aluminum.
- the at least one nucleating agent may comprise an element or compound having a solid solubility in aluminum of, by weight, less than or equal to 2.0% at the second temperature.
- a method of manufacturing a three-dimensional aluminum alloy part may comprise the following step.
- an aluminum alloy powder feed material may be provided.
- a layer of the powder feed material may be distributed over a substrate.
- selective regions of the layer of the powder feed material may be scanned with a high-energy laser or electron beam to form a pool of molten aluminum alloy material therein.
- the selective regions of the layer of the powder feed material may correspond to a cross-section of an aluminum alloy part being formed.
- the laser or electron beam may be terminated to cool and solidify the pool of molten aluminum alloy material into a solid layer of fused aluminum alloy material.
- Steps (b) through (d) may be sequentially repeated to form an aluminum alloy part made up of a plurality of solid layers of fused aluminum alloy material.
- solid phase particles may form within a solution of liquid phase aluminum prior to formation of solid phase aluminum dendrites.
- Each of the solid layers of fused aluminum alloy material in the aluminum alloy part may include a continuous aluminum matrix phase that exhibits a polycrystalline structure and predominantly includes a plurality of equiaxed grains.
- the pool of molten aluminum alloy material may be cooled at a rate in the range of 10 4 Kelvin per second to 10 6 Kelvin per second.
- the molten aluminum alloy material may transition from an entirely liquid phase to a multiphase system.
- the solid phase particles may be dispersed throughout the solution of liquid phase aluminum.
- the solid phase particles may serve as nuclei for the subsequent formation of the solid phase aluminum dendrites.
- the solid phase aluminum dendrites may nucleate and grow in multiple directions on the solid phase particles. Growth of the solid phase aluminum dendrites may be arrested when neighboring aluminum dendrites impinge upon one another and form grain boundaries.
- each particle of the aluminum alloy powder feed material may comprise, by weight, 13-25% silicon.
- the solid phase particles may comprise particles of silicon.
- Each particle of the aluminum alloy powder feed material also may comprise, by weight: greater than 0% iron and less than 9% iron, and greater than 0% manganese and less than 5% manganese.
- the solid phase particles may comprise the particles of silicon and iron-containing intermetallic particles.
- Each particle of the aluminum alloy powder feed material also may comprise, by weight, 0.1-10% copper and 0-2% magnesium.
- the aluminum alloy part may be heated at a temperature in the range of 180° C. to 210° C. for a duration of 0.5 hours to 7 hours to form at least one copper-containing precipitate phase within the aluminum matrix phase of each of the solid layers of fused aluminum alloy material in the aluminum alloy part.
- each particle of the aluminum alloy powder feed material may comprise, by weight: greater than 95% aluminum, and greater than 0% and less than 5% of at least one nucleating agent.
- the at least one nucleating agent may comprise an element or compound having a solid solubility in aluminum of, by weight, less than 0.5% at temperatures less than 530 degrees Celsius.
- each particle of the aluminum alloy powder feed material may comprise, by weight, greater than 98% aluminum and less than 2% of the at least one nucleating agent.
- the at least one nucleating agent may comprise at least one element or compound of titanium (Ti), boron (B), beryllium (Be), cobalt (Co), chromium (Cr), cesium (Cs), iron (Fe), hafnium (Hf), manganese (Mn), molybdenum (Mo), niobium (Nb), lead (Pb), sulfur (S), zirconium (Zr), antimony (Sb), scandium (Sc), selenium (Se), strontium (Sr), tantalum (Ta), vanadium (V), or tungsten (W).
- each particle of the aluminum alloy powder feed material may comprise, by weight, at least one of greater than 0% B and less than 5% B, greater than or equal to 0.7% Be and less than 5% Be, greater than or equal to 0.9% Co and less than 5% Co, greater than or equal to 0.3% Cr and less than 5% Cr, greater than 0% Cs and less than 5% Cs, greater than or equal to 1.7% Fe and less than 5% Fe, greater than or equal to 0.4% Hf and less than 5% Hf, greater than or equal to 1.8% Mn and less than 5% Mn, greater than 0% Mo and less than 5% Mo, greater than 0% Nb and less than 5% Nb, greater than or equal to 1.4% Pb and less than 5% Pb, greater than 0% S and less than 5% S, greater than or equal to 0.9% Sb and less than 5% Sb, greater than or equal to 0.4% Sc and less than 5% Sc, greater than 0% Se and less than 5% Se, greater than or equal to 0.5% Sr and less than
- each particle of the aluminum alloy powder feed material may comprise, by weight, greater than 0.12% Ti, less than 5% Ti, and aluminum as balance.
- FIG. 1 is a temperature (° C.) vs. composition equilibrium phase diagram of a binary Al—Si alloy system
- FIG. 2 is a schematic perspective view of an apparatus for manufacturing aluminum alloy parts via a powder bed fusion additive manufacturing process using an aluminum alloy powder feed material, in accordance with one embodiment of the present disclosure
- FIG. 3 is a magnified view of a layer of the aluminum alloy powder feed material distributed over a previously solidified layer of aluminum alloy material on a building platform of the apparatus of FIG. 2 ;
- FIG. 4 is a magnified view of a laser beam impinging upon and melting the layer of the aluminum alloy powder feed material of FIG. 3 ;
- FIG. 5 is a schematic illustration of a plurality of columnar-shaped aluminum dendrites growing in epitaxy with a surface of a substrate during solidification of a conventional aluminum alloy
- FIG. 6 is a schematic illustration of a plurality of unidirectionally solidified columnar grains formed within the conventional aluminum alloy of FIG. 5 after solidification thereof;
- FIG. 7 is a schematic illustration of a plurality of solid phase particles serving as nuclei for the subsequent nucleation and growth of aluminum dendrites during solidification of the presently disclosed aluminum alloys.
- FIG. 8 is a schematic illustration of a plurality of equiaxed grains formed within the aluminum alloy of FIG. 7 after solidification thereof.
- the presently disclosed aluminum alloys can be prepared in powder form and used in various powder bed fusion additive manufacturing processes to produce three-dimensional aluminum alloy parts that predominantly exhibit an equiaxed grain structure and relatively high resistance to solidification cracking, as compared to aluminum alloy parts that predominantly exhibit a columnar grain structure.
- the aluminum alloys include at least one element or compound that, during solidification of the aluminum alloys, nucleates within a solution of liquid phase aluminum and serves as nuclei for the subsequent nucleation and growth of aluminum dendrites. As the aluminum dendrites grow outward in all directions from their respective nuclei, the aluminum dendrites eventually impinge upon neighboring dendrites and form grain boundaries.
- the formation of columnar grains within the solidifying alloy is prevented or inhibited.
- aluminum alloy refers to a material that comprises, by weight, greater than or equal to 50% aluminum (Al) and one or more other elements selected to impart certain desirable properties to the material that are not exhibited by pure aluminum.
- an aluminum alloy composition for manufacturing a three-dimensional high-strength aluminum alloy part by an additive manufacturing process may comprise, in addition to aluminum, alloying elements of silicon (Si) and copper (Cu), and thus may be referred to herein as an “Al—Si—Cu alloy.” More specifically, the Al—Si—Cu alloy may comprise, by weight, greater than or equal to 13%, 15%, or 19% silicon; less than 25%, 22%, or 21% silicon; or between 13-25%, 15-22%, or 19-21% silicon.
- the Al—Si—Cu alloy may comprise, by weight, greater than or equal to 0.1%, 2%, or 3.5% copper; less than 10%, 5.1%, or 4.1%, copper; or between 0.1-10%, 2-5.1%, or 3.5-4.1% copper.
- FIG. 1 depicts an equilibrium phase diagram 10 for a binary Al—Si alloy.
- a binary Al—Si alloy that includes, by weight, about 12.6% Si and the balance Al is a eutectic composition, as indicated by the presence of a eutectic-type invariant point 12 at such composition on the binary Al—Si equilibrium phase diagram 10 .
- the liquidus lines 14 and the solidus line 16 intersect and, at equilibrium, a liquid phase (L) and two solid phases, i.e., Al (s) and solid Si (s) , coexist.
- Binary Al—Si alloys that include, by weight, greater than 12.6% Si and the balance Al (such as the presently disclosed Al—Si—Cu alloy) contain more Si than the Al—Si eutectic composition and thus are referred to as hypereutectic compositions. As shown in FIG.
- the Al—Si alloy will eventually transition to an entirely solid phase including an aluminum matrix phase and a dispersed phase of silicon (Al (s) +Si (s) ).
- Al (s) +Si (s) a binary Al—Si alloy having a eutectic or hypereutectic composition
- the solidification behavior of a binary Al—Si alloy having a eutectic or hypereutectic composition may be due, at least in part, to the exceptionally low solubility of silicon in aluminum and the relatively high melting point of silicon (m.p. ⁇ 1414° C.) as compared to that of aluminum (m.p. ⁇ 660° C.).
- the amount of silicon in the Al—Si—Cu alloy described herein is selected so that the Al—Si—Cu alloy exhibits a hypereutectic composition and can be heated to a temperature above a liquidus temperature of the Al—Si—Cu alloy and subsequently cooled to a temperature below a solidus temperature of the Al—Si—Cu alloy to produce an entirely solid polycrystalline Al—Si—Cu alloy that predominantly exhibits an equiaxed grain structure, instead of a columnar grain structure.
- the equiaxed grain structure of the resulting polycrystalline Al—Si—Cu alloy is due, at least in part, to the solidification behavior of the Al—Si—Cu alloy.
- the Al—Si—Cu alloy when the hypereutectic Al—Si—Cu alloy is heated to a temperature above the liquidus temperature of the Al—Si—Cu alloy and subsequently cooled to a temperature below the liquidus temperature of the Al—Si—Cu alloy, the Al—Si—Cu alloy will transition from an entirely liquid phase to a multiphase system. During this transition, particles of solid phase silicon will nucleate throughout a solution of liquid phase aluminum to produce a multiphase system that includes a solution of liquid phase aluminum and a solid phase of silicon particles dispersed throughout the liquid phase aluminum.
- Nucleation of the particles of solid phase silicon may occur simultaneously throughout multiple horizontally and vertically spaced-apart regions of the solution of liquid phase aluminum, and may occur generally homogeneously throughout the solution of liquid phase aluminum. Thereafter, when the hypereutectic Al—Si—Cu alloy is further cooled to a temperature at or below the solidus temperature of the Al—Si—Cu alloy, solid phase aluminum dendrites will nucleate and grow in multiple directions on the previously formed silicon particles. Growth of these aluminum dendrites will eventually be arrested when neighboring aluminum dendrites impinge upon one another and form grain boundaries.
- the Al—Si—Cu alloy After the hypereutectic Al—Si—Cu alloy has completely solidified, the Al—Si—Cu alloy will exhibit a polycrystalline structure including a continuous aluminum matrix phase and a dispersed phase of silicon. In addition, the resulting hypereutectic Al—Si—Cu alloy will predominantly include a plurality of randomly oriented equiaxed grains, instead of columnar grains.
- the equiaxed grains may have a mean grain diameter in the range of 0.1 ⁇ m to 50 ⁇ m.
- the Al—Si—Cu alloy may have a liquidus temperature in the range of 570° C. to 850° C., and a solidus temperature in the range of 500° C. to 540° C. As such, the Al—Si—Cu alloy may exhibit a multiphase system of liquid phase aluminum and solid phase silicon at a temperature in the range of 500° C. to 850° C.
- the term “predominantly” means something, for example, a grain structure, that is present in the greatest amount by volume, as compared to other similar things, for example, as compared to other grain structures.
- the amount of copper in the Al—Si—Cu alloy is selected to provide the alloy with the ability to develop one or more Cu-containing precipitate phases within the aluminum matrix phase when the Al—Si—Cu alloy is subjected to a heat treatment process.
- the amount of copper in the Al—Si—Cu alloy may be selected to provide the alloy with the ability to develop an Al- and Cu-based precipitate (referred to herein as an “AlCu precipitate”) phase within the aluminum matrix phase when the Al—Si—Cu alloy is subjected to a heat treatment process that includes an aging heat treatment stage and optionally a solution heat treatment stage.
- the AlCu precipitate phase is Al- and Cu-based, meaning that Al and Cu constitute the largest constituents of the precipitate phase by weight.
- Formation of the AlCu precipitate phase within the aluminum matrix phase may provide the Al—Si—Cu alloy with high strength at relatively low temperatures, e.g., at ambient temperature (e.g., 25° C.) and at temperatures up to about 200° C.
- the Al—Si—Cu alloy also may comprise alloying elements of magnesium (Mg), iron (Fe), and/or manganese (Mn).
- the Al—Si—Cu alloy may comprise, by weight, greater than or equal to 0%, 0.5%, or 0.6% magnesium; less than 2%, 1.5%, or 0.8% magnesium; or between 0-2%, 0.5-1.5%, or 0.6-0.8% magnesium.
- the Al—Si—Cu alloy may comprise, by weight, greater than or equal to 0% or 7% iron; less than 10% or 9% iron; or between 0-10% or 7-9% iron.
- the Al—Si—Cu alloy may comprise, by weight, greater than or equal to 0% or 3% manganese; less than 6% or 5% manganese; or between 0-6% or 3-5% manganese.
- the amount of magnesium in the Al—Si—Cu alloy may be selected to provide the alloy with the ability to develop an Al-, Cu-, Mg-, and Si-based precipitate (referred to herein as an “AlCuMgSi precipitate”) phase within the aluminum matrix phase when the Al—Si—Cu alloy is subjected to a heat treatment process that includes an aging heat treatment stage and optionally a solution heat treatment stage.
- the AlCuMgSi precipitate phase is Al-, Cu-, Mg-, and Si-based, meaning that Al, Cu, Mg, and Si constitute the largest constituents of the precipitate phase by weight.
- Formation of the AlCuMgSi precipitate phase within the aluminum matrix phase may provide the Al—Si—Cu alloy with high strength at ambient temperature and at elevated temperatures (e.g., up to about 300° C.).
- the amount of iron and manganese in the Al—Si—Cu alloy may be selected to promote the formation of at least one intermetallic phase within the Al—Si—Cu alloy during solidification thereof.
- the amount of iron and/or manganese in the Al—Si—Cu alloy may be selected so that at least one intermetallic phase nucleates within the liquid phase aluminum during solidification of the Al—Si—Cu alloy and provides additional nucleation sites (in addition to the nucleation sites provided by the silicon particles) for the subsequent nucleation and equiaxed growth of aluminum dendrites.
- the at least one intermetallic phase may comprise an Fe-containing intermetallic phase and/or a Mn-containing intermetallic phase.
- the amount of iron in the Al—Si—Cu alloy may be selected to promote the formation of solid particles of an Al-, Fe-, and Si-based intermetallic (referred to herein as an “AlFeSi intermetallic”) phase within the liquid phase aluminum during solidification of the Al—Si—Cu alloy.
- the AlFeSi intermetallic phase is Al-, Fe-, and Si-based, meaning that Al, Fe, and Si are the largest constituents of the intermetallic phase.
- the combined amounts of Al, Fe, and Si in the AlFeSi intermetallic phase may account for, by weight, greater than 50% of the AlFeSi intermetallic phase and, in some cases, greater than 90% of the AlFeSi intermetallic phase.
- the amount of manganese in the Al—Si—Cu alloy may be selected to promote the formation of an Al-, Fe-, Mn-, and Si-based intermetallic (referred to herein as an “AlFeMnSi intermetallic”) phase within the liquid phase aluminum during solidification of the Al—Si—Cu alloy and to inhibit the formation of an Al-, Fe-, and Si-based intermetallic (referred to herein as an “AlFeSi intermetallic”) phase.
- the hypereutectic Al—Si—Cu alloy does not require addition of scandium (Sc) to achieve an equiaxed grain structure during solidification thereof.
- the amount of Sc in the Al—Si—Cu alloy may be less than 0.2%, preferably less than 0.05%, and more preferably less than 0.01% by weight of the Al—Si—Cu alloy.
- Additional elements not intentionally introduced into the composition of the Al—Si—Cu alloy nonetheless may be inherently present in the alloy in relatively small amounts, for example, less than 0.2%, preferably less than 0.05%, and more preferably less than 0.01% by weight of the Al—Si—Cu alloy. Such elements may be present, for example, as impurities in the raw materials used to prepare the Al—Si—Cu alloy composition.
- the Al—Si—Cu alloy is referred to as comprising one or more alloying elements (e.g., one or more of Si, Cu, Mg, Fe, and Mn) and aluminum as balance
- the term “as balance” does not exclude the presence of additional elements not intentionally introduced into the composition of the Al—Si—Cu alloy but nonetheless inherently present in the alloy in relatively small amounts, e.g., as impurities.
- an aluminum alloy composition for manufacturing a three-dimensional high thermal conductivity aluminum alloy part by an additive manufacturing process may comprise, by weight, greater than or equal to 95% aluminum and less than 5% of at least one nucleating agent, and thus may be referred to as a “high-purity Al alloy.”
- the high-purity Al alloy may comprise, by weight, greater than or equal to 98% aluminum and less than 2% of at least one nucleating agent.
- the at least one nucleating agent included in the high-purity Al alloy may comprise an element or compound that exhibits relatively low solid solubility (e.g., less than 1 wt % or, more preferably, less than 0.5 wt %) in aluminum at temperatures less than 530° C.
- the composition and amount of the at least one nucleating agent included in the high-purity Al alloy may be selected so that the high-purity Al alloy can be heated to a temperature above a liquidus temperature of the high-purity Al alloy and subsequently cooled to a temperature below a solidus temperature of the high-purity Al alloy to produce an entirely solid polycrystalline high-purity Al alloy that predominantly exhibits an equiaxed grain structure, instead of a columnar grain structure.
- the composition and amount of the at least one nucleating agent in the high-purity Al alloy may be selected so that, when the high-purity Al alloy is melted and subsequently cooled from an entirely liquid phase to an entirely solid phase, particles of the at least one nucleating agent will form within a solution of liquid phase aluminum prior to formation of a solid aluminum matrix phase. More specifically, when the high-purity Al alloy is heated to a temperature above the liquidus temperature of the high-purity Al alloy and subsequently cooled to a temperature below the liquidus temperature of the high-purity Al alloy, the high-purity Al alloy will transition from an entirely liquid phase to a multiphase system.
- solid particles of the at least one nucleating agent will nucleate throughout a solution of liquid phase aluminum to produce a multiphase system that includes a solution of liquid phase aluminum and a solid phase of particles of the at least one nucleating agent dispersed throughout the liquid phase aluminum.
- the solid particles of the at least one nucleating agent may exhibit a solubility in liquid aluminum of, by weight, less than or equal to 2%, which may help maximize the number if solid particles within the liquid phase aluminum.
- Nucleation of the solid particles of the at least one nucleating agent may occur simultaneously throughout multiple horizontally and vertically spaced-apart regions of the solution of liquid phase aluminum, and may occur generally homogeneously throughout the solution of liquid phase aluminum.
- solid phase aluminum dendrites will nucleate and grown in multiple directions on the previously formed nuclei (i.e., on the solid particles of the at least one nucleating agent). Growth of these aluminum dendrites within the solidifying high-purity Al alloy will eventually be arrested when neighboring aluminum dendrites impinge upon one another and form grain boundaries.
- the high-purity Al alloy After the high-purity Al alloy has been cooled to a temperature below the solidus temperature of the high-purity Al alloy and is completely solidified, the high-purity Al alloy will exhibit a polycrystalline structure including a continuous aluminum matrix phase and a dispersed phase of particles of the at least one nucleating agent.
- the resulting high-purity Al alloy will predominantly include a plurality of randomly oriented equiaxed grains, instead of columnar grains.
- the equiaxed grains may have a mean diameter in the range of 0.1 ⁇ m to 50 ⁇ m.
- the high-purity Al alloy may have a liquidus temperature in the range of 660° and 1300° C. and a solidus temperature in the range of 650° and 680° C. As such, the high-purity Al alloy may exhibit a multiphase system of liquid phase aluminum and solid particles of the at least one nucleating agent at a temperature in the range of 650° and 1300° C.
- the high-purity Al alloy may exhibit a thermal conductivity in the range of 120 watts per meter-Kelvin (W/(m ⁇ K)) to 220 W/(m ⁇ K).
- the at least one nucleating agent may comprise an element that, when present in the high-purity Al alloy, exhibits a eutectic point or a peritectic point at a concentration of, by weight, less than 5% of the high-purity Al alloy.
- the element may be present in the high-purity Al alloy in an amount that is greater than the amount of the same element in the eutectic or peritectic composition of the Al alloy.
- the at least one nucleating agent may comprise titanium (Ti).
- Ti titanium
- a binary Al—Ti alloy exhibits a peritectic point at a composition of, by weight, about 0.12% Ti and a temperature of about 665° C. Therefore, in one form, the high-purity Al alloy may comprise a high-purity Al—Ti alloy including, by weight, greater than or equal to 95% aluminum, greater than 0.12% titanium, and less than 5% titanium.
- solid particles of Al 3 Ti will nucleate within a solution of liquid phase aluminum at the liquidus temperature of the alloy. Thereafter, aluminum dendrites will nucleate and grown in all directions on the previously formed Al 3 Ti particles, resulting in the formation of a polycrystalline structure that predominantly includes a plurality of randomly oriented equiaxed grains, instead of columnar grains.
- the high-purity Al alloy may include, by weight, equal to or greater than 0% B to 5% B, 0.7-5% Be, 0.9-5% Co, 0.3-5% Cr, equal to or greater than 0% Cs to 5% Cs, 1.7-5% Fe, 0.4-5% Hf, 1.8-5% Mn, equal to or greater than 0% Mo to 5% Mo, equal to or greater than 0% Nb to 5% Nb, 1.4-5% Pb, equal to or greater than 0% S to 5% S, 0.9-5% Sb, 0.4-5% Sc, equal to or greater than 0% Se to 5% Se, 0.5-5% Sr, equal to or greater than 0% Ta to 5% Ta, 0.12-5% Ti, equal to or greater than 0% V to 5% V, equal to or greater than 0% W to 5% W, and/or equal to or greater than 0% Zr to 5% Zr, and the balance Al.
- the high-purity Al alloy may include one or more additional elements that may or may not be intentionally introduced into the composition of the high-purity Al alloy, with such additional elements being present in the high-purity Al alloy in amounts less than 0.2%, preferably less than 0.05%, and more preferably less than 0.01% by weight of the high-purity Al alloy. Additional elements not intentionally introduced into the composition of the high-purity Al alloy may be present, for example, as impurities in the raw materials used to prepare the high-purity Al alloy composition.
- the high-purity Al alloy is referred to as comprising at least one nucleating agent (e.g., at least one element or compound of Ti, B, Be, Co, Cr, Cs, Fe, Hf, Mn, Mo, Nb, Pb, S, Zr, Sb, Sc, Se, Sr, Ta, V, or W) and aluminum as balance
- nucleating agent e.g., at least one element or compound of Ti, B, Be, Co, Cr, Cs, Fe, Hf, Mn, Mo, Nb, Pb, S, Zr, Sb, Sc, Se, Sr, Ta, V, or W
- aluminum e.g., aluminum
- the term “as balance” does not exclude the presence of additional elements not intentionally introduced into the composition of the high-purity Al alloy but nonetheless inherently present in the alloy in relatively small amounts, e.g., as impurities.
- FIG. 2 depicts an apparatus 100 that can be used to manufacture a three-dimensional aluminum alloy part 108 from an aluminum alloy powder feed material 110 , which may comprise or consist of the Al—Si—Cu alloy and/or the high-purity Al alloy.
- the three-dimensional aluminum alloy part 108 may be formed via a powder bed fusion additive manufacturing process, in which digital design data is used to build up the part 108 layer by layer.
- the apparatus 100 may be configured to manufacture the aluminum alloy part 108 by a powder bed fusion process, which may be carried out using a selective laser melting or an electron beam melting technique.
- the apparatus 100 may comprise a building chamber 112 including a building platform 114 , a powder feed material reservoir 116 separated from the building chamber 112 by a weir 118 , and a high-power energy beam source 120 .
- a volume of the aluminum alloy powder feed material 110 may be distributed over a surface of the building platform 114 , for example, by a blade 122 to form a layer 124 of aluminum alloy powder feed material 110 .
- the aluminum alloy powder feed material 110 may have a mean particle diameter in the range of 5 micrometers to 100 micrometers and the layer 124 of aluminum alloy powder feed material 110 may have a thickness in the range of 20 micrometers to 100 micrometers.
- the layer 124 of powder feed material 110 is distributed over a surface of the building platform 114 and also over a surface of one or more previously melted, fused, and solidified aluminum alloy layers 126 ( FIG. 3 ).
- selective regions 128 of the layer 124 are scanned by a high-energy laser or electron beam 130 .
- the selective regions 128 of the layer 124 scanned by the beam 130 correspond to a cross-section of the three-dimensional aluminum alloy part 108 being formed.
- the beam 130 scans the selective regions 128 of the layer 124 , the beam 130 impinges the layer 124 and heat generated by absorption of energy from the beam 130 initiates melting of the layer 124 within the selective regions 128 .
- a pool of molten aluminum alloy material 132 is created that fully penetrates the layer 124 and extends through the layer 124 in a direction substantially perpendicular to the surface of the building platform 114 (i.e., along the z-axis).
- the pool of molten aluminum alloy material 132 may extend into the layer 124 and partially into the underlying layers 126 at a depth in the range of 10 ⁇ m to 300 ⁇ m.
- the pool of molten aluminum alloy material 132 After termination of the high-energy beam 130 , the pool of molten aluminum alloy material 132 rapidly cools and solidifies to form another solidified aluminum alloy layer that bonds with the previously solidified layers 126 .
- the pool of molten aluminum alloy material 132 may cool at a rate in the range of 10 4 Kelvin per second to 10 6 Kelvin per second.
- the reservoir 116 may be raised in a build direction (i.e., along the z-axis), or the building platform 114 may be lowered, by a thickness of the newly solidified layer, for example, by a piston 134 .
- a further layer of powder feed material 110 may be distributed over the surface of the building platform 114 and over the previously solidified aluminum alloy layers 126 , scanned with the high-energy beam 130 in regions corresponding to another cross-section of the three-dimensional aluminum alloy part 108 , and solidified to form yet another solidified aluminum alloy layer that bonds with the previously solidified layers 126 . This process is repeated until the entire alloy part 108 is built up layer-by-layer.
- the resulting alloy part 108 may be heat treated to dissolve into solid solution any coarse intermetallic phases that may have formed during solidification and/or to promote the formation of one or more Cu-containing precipitate phases (e.g., an AlCu precipitate phase and/or AlCuMgSi precipitate phase) within the aluminum matrix phase.
- the heat treatment process may include an aging heat treatment stage and optionally a solution heat treatment stage. If performed, the solution heat treatment stage may be performed prior to the aging heat treatment stage. During the optional solution heat treatment stage, the alloy part 108 may be heated to a temperature in the range of 490° C. to 550° C. for a duration of 10 minutes to 10 hours.
- the alloy part 108 may be heated during the solution heat treatment stage to a temperature in the range of 490° C. to 550° C. for a duration of 3 hours to 10 hours. In another form, the alloy part 108 may be heated during the solution heat treatment stage to a temperature in the range of 490° C. to 550° C. for a duration of less than 1 hours, for example, for a duration of 10 minutes to 30 minutes. After the optional solution heat treatment stage, the alloy part 108 may be cooled or quenched to a temperature less than 100° C., e.g., ambient temperature, at a cooling rate sufficient to prevent diffusion and precipitation of alloying elements dissolved in into solid solution during the solution heat treatment stage.
- a temperature less than 100° C. e.g., ambient temperature
- the alloy part 108 may be heated to a temperature in the range of 180° C. to 210° C. for a duration of 0.5 hours to 7 hours. After the aging heat treatment stage, the alloy part 108 may be cooled or quenched to a temperature less than 100° C., e.g., ambient temperature.
- the Al—Si—Cu alloy and the high-purity Al alloy each include at least one element or compound that, during solidification of the alloy, nucleates within a solution of liquid phase aluminum and provides sites for the subsequent nucleation and growth of aluminum dendrites.
- FIGS. 5 and 6 it has been found that, when aluminum alloys that do not include such elements and/or compounds (or do not include appropriate amounts of such elements and/or compounds) are melted and subsequently solidified, columnar-shaped aluminum dendrites 236 tend to grow unidirectionally within the solidifying aluminum alloys and in epitaxy with a surface of an adjacent solid substrate 238 ( FIG. 5 ). As shown in FIG.
- the resulting aluminum alloys exhibit a columnar grain structure including a plurality of unidirectional columnar grains 240 .
- columnar-shaped aluminum dendrites tend to grow unidirectionally in the build direction (i.e., along the z-axis) and in epitaxy with the surface of the building platform 114 or with the surface of one or more previously solidified aluminum alloy layers 126 .
- this unidirectional epitaxial aluminum dendrite growth tends to persist through each of the subsequently melted and solidified layers of the aluminum alloy part being formed, with the resulting aluminum alloy part being readily susceptible to the formation of cracks along the grain boundaries between the adjacent elongated columnar grains 240 .
- the solid particles 342 may comprise particles of substantially pure silicon and optionally particles of an Fe- and/or Mn-containing intermetallic phase.
- the solid particles 342 may comprise an element or compound of Ti, B, Be, Co, Cr, Cs, Fe, Hf, Mn, Mo, Nb, Pb, S, Zr, Sb, Sc, Se, Sr, Ta, and/or V, as described above in further detail.
- solid phase aluminum dendrites 346 will nucleate and grown in all directions on the solid particles 342 , as shown in FIG. 7 .
- Additional aluminum dendrites 347 also may grow in epitaxy with a surface of an adjacent substrate 338 . Growth of the aluminum dendrites 346 , 347 within the solidifying liquid phase aluminum 344 will eventually be arrested when neighboring aluminum dendrites 346 , 347 impinge upon one another and form grain boundaries 348 , as shown in FIG. 8 .
- the resulting aluminum alloys will exhibit an equiaxed grain structure including a plurality of randomly oriented equiaxed grains 350 .
- any columnar-shaped aluminum dendrites 347 originating on (e.g., growing in epitaxy with) the surface of the building platform 114 or on the surface of one or more previously solidified aluminum alloy layers 126 are stopped by the aluminum dendrites 346 growing in multiple random directions from the solid particles 342 distributed throughout the bulk of each layer of solidifying aluminum alloy material.
Abstract
Description
- A variety of aluminum alloy compositions have been developed for use in the manufacture of three-dimensional aluminum alloy parts via casting and/or hot forming operations to impart certain desirable chemical and mechanical properties to the resulting parts. However, it has been found that when such aluminum alloy compositions are employed as a powder feed material in a powder bed fusion additive manufacturing process, the resulting aluminum alloy parts oftentimes exhibit a columnar grain structure, and thus are relatively susceptible to cracking along grain boundaries between adjacent columnar grains. Therefore, there is a need in the art for an aluminum alloy composition that can be employed in a powder bed fusion additive manufacturing process to form three-dimensional aluminum alloy parts that predominantly exhibit an equiaxed grain structure and thus are relatively resistant or impervious to solidification cracking.
- In accordance with one aspect of the present disclosure, an aluminum alloy powder for manufacturing a three-dimensional high-strength aluminum alloy part by a powder bed fusion additive manufacturing process is provided. Each particle of the aluminum alloy powder may comprise an aluminum alloy that includes, by weight, 13-25% silicon, 0.1-10% copper, and 0-2% magnesium. When the aluminum alloy is heated to a first temperature greater than a liquidus temperature of the aluminum alloy and subsequently cooled to a second temperature less than the liquidus temperature of the aluminum alloy and greater than a solidus temperature of the aluminum alloy, the aluminum alloy may transition from a liquid phase to a multiphase system. The multiphase system may include a solution of liquid phase aluminum and a solid phase of silicon particles dispersed throughout the liquid phase aluminum.
- In one form, the aluminum alloy may comprise, by weight, 15-22% silicon, 2-5.1% copper, and 0.6-0.8% magnesium. In another form, the aluminum alloy powder may comprise, by weight, 19-21% silicon, 3.5-4.1% copper, and aluminum as balance.
- The aluminum also may comprise, by weight: greater than 0% iron and less than 9% iron, and greater than 0% manganese and less than 5% manganese. In such case, the multiphase system may include the solution of liquid phase aluminum, the solid phase of silicon particles, and another solid phase of iron-containing intermetallic particles dispersed throughout the liquid phase aluminum.
- In accordance with another aspect of the present disclosure, an aluminum alloy powder for manufacturing a three-dimensional high thermal conductivity aluminum alloy part by a powder bed fusion additive manufacturing process is provided. Each particle of the aluminum alloy powder may comprise an aluminum alloy that includes, by weight: greater than 95% aluminum, and greater than 0% and less than 5% of at least one nucleating agent. The at least one nucleating agent may comprise an element or compound having a solid solubility in aluminum of, by weight, less than 0.5% at temperatures less than 530 degrees Celsius. When the aluminum alloy is heated to a first temperature greater than a liquidus temperature of the aluminum alloy and subsequently cooled to a second temperature less than the liquidus temperature of the aluminum alloy and greater than a solidus temperature of the aluminum alloy, the aluminum alloy may transition from a liquid phase to a multiphase system. The multiphase system may include a solution of liquid phase aluminum and a solid phase of particles of the at least one nucleating agent dispersed throughout the liquid phase aluminum. In one form, the at least one nucleating agent may comprise an element or compound having a solid solubility in aluminum of, by weight, less than or equal to 2.0% at the second temperature.
- A method of manufacturing a three-dimensional aluminum alloy part may comprise the following step. In step (a), an aluminum alloy powder feed material may be provided. In step (b), a layer of the powder feed material may be distributed over a substrate. In step (c), selective regions of the layer of the powder feed material may be scanned with a high-energy laser or electron beam to form a pool of molten aluminum alloy material therein. The selective regions of the layer of the powder feed material may correspond to a cross-section of an aluminum alloy part being formed. In step (d), the laser or electron beam may be terminated to cool and solidify the pool of molten aluminum alloy material into a solid layer of fused aluminum alloy material. Steps (b) through (d) may be sequentially repeated to form an aluminum alloy part made up of a plurality of solid layers of fused aluminum alloy material. During solidification of the pool of molten aluminum alloy material, solid phase particles may form within a solution of liquid phase aluminum prior to formation of solid phase aluminum dendrites. Each of the solid layers of fused aluminum alloy material in the aluminum alloy part may include a continuous aluminum matrix phase that exhibits a polycrystalline structure and predominantly includes a plurality of equiaxed grains.
- After termination of the laser or electron beam, the pool of molten aluminum alloy material may be cooled at a rate in the range of 104 Kelvin per second to 106 Kelvin per second.
- During solidification of the pool of molten aluminum alloy material, the molten aluminum alloy material may transition from an entirely liquid phase to a multiphase system. In the multiphase system, the solid phase particles may be dispersed throughout the solution of liquid phase aluminum.
- The solid phase particles may serve as nuclei for the subsequent formation of the solid phase aluminum dendrites. In such case, after the solid phase particles form within the solution of liquid phase aluminum, the solid phase aluminum dendrites may nucleate and grow in multiple directions on the solid phase particles. Growth of the solid phase aluminum dendrites may be arrested when neighboring aluminum dendrites impinge upon one another and form grain boundaries.
- In one form, each particle of the aluminum alloy powder feed material may comprise, by weight, 13-25% silicon. In such case, the solid phase particles may comprise particles of silicon.
- Each particle of the aluminum alloy powder feed material also may comprise, by weight: greater than 0% iron and less than 9% iron, and greater than 0% manganese and less than 5% manganese. In such case, the solid phase particles may comprise the particles of silicon and iron-containing intermetallic particles.
- Each particle of the aluminum alloy powder feed material also may comprise, by weight, 0.1-10% copper and 0-2% magnesium. In such case, the aluminum alloy part may be heated at a temperature in the range of 180° C. to 210° C. for a duration of 0.5 hours to 7 hours to form at least one copper-containing precipitate phase within the aluminum matrix phase of each of the solid layers of fused aluminum alloy material in the aluminum alloy part.
- In another form, each particle of the aluminum alloy powder feed material may comprise, by weight: greater than 95% aluminum, and greater than 0% and less than 5% of at least one nucleating agent. The at least one nucleating agent may comprise an element or compound having a solid solubility in aluminum of, by weight, less than 0.5% at temperatures less than 530 degrees Celsius.
- In one specific example, each particle of the aluminum alloy powder feed material may comprise, by weight, greater than 98% aluminum and less than 2% of the at least one nucleating agent.
- The at least one nucleating agent may comprise at least one element or compound of titanium (Ti), boron (B), beryllium (Be), cobalt (Co), chromium (Cr), cesium (Cs), iron (Fe), hafnium (Hf), manganese (Mn), molybdenum (Mo), niobium (Nb), lead (Pb), sulfur (S), zirconium (Zr), antimony (Sb), scandium (Sc), selenium (Se), strontium (Sr), tantalum (Ta), vanadium (V), or tungsten (W).
- In one form, each particle of the aluminum alloy powder feed material may comprise, by weight, at least one of greater than 0% B and less than 5% B, greater than or equal to 0.7% Be and less than 5% Be, greater than or equal to 0.9% Co and less than 5% Co, greater than or equal to 0.3% Cr and less than 5% Cr, greater than 0% Cs and less than 5% Cs, greater than or equal to 1.7% Fe and less than 5% Fe, greater than or equal to 0.4% Hf and less than 5% Hf, greater than or equal to 1.8% Mn and less than 5% Mn, greater than 0% Mo and less than 5% Mo, greater than 0% Nb and less than 5% Nb, greater than or equal to 1.4% Pb and less than 5% Pb, greater than 0% S and less than 5% S, greater than or equal to 0.9% Sb and less than 5% Sb, greater than or equal to 0.4% Sc and less than 5% Sc, greater than 0% Se and less than 5% Se, greater than or equal to 0.5% Sr and less than 5% Sr, greater than 0% Ta and less than 5% Ta, greater than or equal to 0.12% Ti and less than 5% Ti, greater than 0% V and less than 5% V, greater than 0% W and less than 5% W, or greater than 0% Zr and less than 5% Zr.
- In one specific form, each particle of the aluminum alloy powder feed material may comprise, by weight, greater than 0.12% Ti, less than 5% Ti, and aluminum as balance.
-
FIG. 1 is a temperature (° C.) vs. composition equilibrium phase diagram of a binary Al—Si alloy system; -
FIG. 2 is a schematic perspective view of an apparatus for manufacturing aluminum alloy parts via a powder bed fusion additive manufacturing process using an aluminum alloy powder feed material, in accordance with one embodiment of the present disclosure; -
FIG. 3 is a magnified view of a layer of the aluminum alloy powder feed material distributed over a previously solidified layer of aluminum alloy material on a building platform of the apparatus ofFIG. 2 ; -
FIG. 4 is a magnified view of a laser beam impinging upon and melting the layer of the aluminum alloy powder feed material ofFIG. 3 ; -
FIG. 5 is a schematic illustration of a plurality of columnar-shaped aluminum dendrites growing in epitaxy with a surface of a substrate during solidification of a conventional aluminum alloy; -
FIG. 6 is a schematic illustration of a plurality of unidirectionally solidified columnar grains formed within the conventional aluminum alloy ofFIG. 5 after solidification thereof; -
FIG. 7 is a schematic illustration of a plurality of solid phase particles serving as nuclei for the subsequent nucleation and growth of aluminum dendrites during solidification of the presently disclosed aluminum alloys; and -
FIG. 8 is a schematic illustration of a plurality of equiaxed grains formed within the aluminum alloy ofFIG. 7 after solidification thereof. - The presently disclosed aluminum alloys can be prepared in powder form and used in various powder bed fusion additive manufacturing processes to produce three-dimensional aluminum alloy parts that predominantly exhibit an equiaxed grain structure and relatively high resistance to solidification cracking, as compared to aluminum alloy parts that predominantly exhibit a columnar grain structure. To inhibit the formation of columnar grains within the aluminum alloy parts during the powder bed fusion process, the aluminum alloys include at least one element or compound that, during solidification of the aluminum alloys, nucleates within a solution of liquid phase aluminum and serves as nuclei for the subsequent nucleation and growth of aluminum dendrites. As the aluminum dendrites grow outward in all directions from their respective nuclei, the aluminum dendrites eventually impinge upon neighboring dendrites and form grain boundaries. Because the nucleation and growth of the aluminum dendrites occurs throughout the solidifying aluminum alloy, instead of along a single plane (e.g., on a substrate or on a layer of previously solidified aluminum alloy material), the formation of columnar grains within the solidifying alloy is prevented or inhibited.
- As used herein, the term “aluminum alloy” refers to a material that comprises, by weight, greater than or equal to 50% aluminum (Al) and one or more other elements selected to impart certain desirable properties to the material that are not exhibited by pure aluminum.
- In one form, an aluminum alloy composition for manufacturing a three-dimensional high-strength aluminum alloy part by an additive manufacturing process may comprise, in addition to aluminum, alloying elements of silicon (Si) and copper (Cu), and thus may be referred to herein as an “Al—Si—Cu alloy.” More specifically, the Al—Si—Cu alloy may comprise, by weight, greater than or equal to 13%, 15%, or 19% silicon; less than 25%, 22%, or 21% silicon; or between 13-25%, 15-22%, or 19-21% silicon. In addition, the Al—Si—Cu alloy may comprise, by weight, greater than or equal to 0.1%, 2%, or 3.5% copper; less than 10%, 5.1%, or 4.1%, copper; or between 0.1-10%, 2-5.1%, or 3.5-4.1% copper.
-
FIG. 1 depicts an equilibrium phase diagram 10 for a binary Al—Si alloy. As shown, a binary Al—Si alloy that includes, by weight, about 12.6% Si and the balance Al is a eutectic composition, as indicated by the presence of a eutectic-typeinvariant point 12 at such composition on the binary Al—Si equilibrium phase diagram 10. At theeutectic point 12, theliquidus lines 14 and thesolidus line 16 intersect and, at equilibrium, a liquid phase (L) and two solid phases, i.e., Al(s) and solid Si(s), coexist. Binary Al—Si alloys that include, by weight, greater than 12.6% Si and the balance Al (such as the presently disclosed Al—Si—Cu alloy) contain more Si than the Al—Si eutectic composition and thus are referred to as hypereutectic compositions. As shown inFIG. 1 , when a binary Al—Si alloy having a eutectic composition is cooled through theeutectic point 12, from a first temperature above the solidus line 16 (and above the eutectic temperature (TE) of the alloy (i.e., about 577° C.)) to a second temperature below thesolidus line 16 and below the TE of the alloy, the Al—Si alloy undergoes a eutectic transformation and transitions from an entirely liquid phase (L) to an entirely solid phase (Al(s)+Si(s)). On the other hand, when an Al—Si alloy having a hypereutectic composition is melted to form an entirely liquid phase (L) and is subsequently cooled from a first temperature above theliquidus line 14 to a second temperature below theliquidus line 14, the Al—Si alloy does not directly transition from the liquid phase (L) to an entirely solid phase. Instead, as this hypereutectic Al—Si alloy is cooled to a temperature below theliquidus line 14, the Al—Si alloy transitions to a two-phase system, including a liquid phase (L) of aluminum and a solid phase (Si(s)) of substantially pure silicon particles. If the hypereutectic Al—Si alloy is further cooled to a third temperature below thesolidus line 16, the Al—Si alloy will eventually transition to an entirely solid phase including an aluminum matrix phase and a dispersed phase of silicon (Al(s)+Si(s)). Without intending to be bound by theory, it is believed that the solidification behavior of a binary Al—Si alloy having a eutectic or hypereutectic composition may be due, at least in part, to the exceptionally low solubility of silicon in aluminum and the relatively high melting point of silicon (m.p.˜1414° C.) as compared to that of aluminum (m.p.˜660° C.). - The amount of silicon in the Al—Si—Cu alloy described herein is selected so that the Al—Si—Cu alloy exhibits a hypereutectic composition and can be heated to a temperature above a liquidus temperature of the Al—Si—Cu alloy and subsequently cooled to a temperature below a solidus temperature of the Al—Si—Cu alloy to produce an entirely solid polycrystalline Al—Si—Cu alloy that predominantly exhibits an equiaxed grain structure, instead of a columnar grain structure. Without intending to be bound by theory, it is believed that the equiaxed grain structure of the resulting polycrystalline Al—Si—Cu alloy is due, at least in part, to the solidification behavior of the Al—Si—Cu alloy. In particular, it is believed that, when the hypereutectic Al—Si—Cu alloy is heated to a temperature above the liquidus temperature of the Al—Si—Cu alloy and subsequently cooled to a temperature below the liquidus temperature of the Al—Si—Cu alloy, the Al—Si—Cu alloy will transition from an entirely liquid phase to a multiphase system. During this transition, particles of solid phase silicon will nucleate throughout a solution of liquid phase aluminum to produce a multiphase system that includes a solution of liquid phase aluminum and a solid phase of silicon particles dispersed throughout the liquid phase aluminum. Nucleation of the particles of solid phase silicon may occur simultaneously throughout multiple horizontally and vertically spaced-apart regions of the solution of liquid phase aluminum, and may occur generally homogeneously throughout the solution of liquid phase aluminum. Thereafter, when the hypereutectic Al—Si—Cu alloy is further cooled to a temperature at or below the solidus temperature of the Al—Si—Cu alloy, solid phase aluminum dendrites will nucleate and grow in multiple directions on the previously formed silicon particles. Growth of these aluminum dendrites will eventually be arrested when neighboring aluminum dendrites impinge upon one another and form grain boundaries. After the hypereutectic Al—Si—Cu alloy has completely solidified, the Al—Si—Cu alloy will exhibit a polycrystalline structure including a continuous aluminum matrix phase and a dispersed phase of silicon. In addition, the resulting hypereutectic Al—Si—Cu alloy will predominantly include a plurality of randomly oriented equiaxed grains, instead of columnar grains. The equiaxed grains may have a mean grain diameter in the range of 0.1 μm to 50 μm.
- The Al—Si—Cu alloy may have a liquidus temperature in the range of 570° C. to 850° C., and a solidus temperature in the range of 500° C. to 540° C. As such, the Al—Si—Cu alloy may exhibit a multiphase system of liquid phase aluminum and solid phase silicon at a temperature in the range of 500° C. to 850° C.
- As used herein, the term “predominantly” means something, for example, a grain structure, that is present in the greatest amount by volume, as compared to other similar things, for example, as compared to other grain structures.
- The amount of copper in the Al—Si—Cu alloy is selected to provide the alloy with the ability to develop one or more Cu-containing precipitate phases within the aluminum matrix phase when the Al—Si—Cu alloy is subjected to a heat treatment process. For example, the amount of copper in the Al—Si—Cu alloy may be selected to provide the alloy with the ability to develop an Al- and Cu-based precipitate (referred to herein as an “AlCu precipitate”) phase within the aluminum matrix phase when the Al—Si—Cu alloy is subjected to a heat treatment process that includes an aging heat treatment stage and optionally a solution heat treatment stage. The AlCu precipitate phase is Al- and Cu-based, meaning that Al and Cu constitute the largest constituents of the precipitate phase by weight. Formation of the AlCu precipitate phase within the aluminum matrix phase may provide the Al—Si—Cu alloy with high strength at relatively low temperatures, e.g., at ambient temperature (e.g., 25° C.) and at temperatures up to about 200° C.
- In some embodiments, the Al—Si—Cu alloy also may comprise alloying elements of magnesium (Mg), iron (Fe), and/or manganese (Mn). When present, the Al—Si—Cu alloy may comprise, by weight, greater than or equal to 0%, 0.5%, or 0.6% magnesium; less than 2%, 1.5%, or 0.8% magnesium; or between 0-2%, 0.5-1.5%, or 0.6-0.8% magnesium. The Al—Si—Cu alloy may comprise, by weight, greater than or equal to 0% or 7% iron; less than 10% or 9% iron; or between 0-10% or 7-9% iron. The Al—Si—Cu alloy may comprise, by weight, greater than or equal to 0% or 3% manganese; less than 6% or 5% manganese; or between 0-6% or 3-5% manganese.
- The amount of magnesium in the Al—Si—Cu alloy may be selected to provide the alloy with the ability to develop an Al-, Cu-, Mg-, and Si-based precipitate (referred to herein as an “AlCuMgSi precipitate”) phase within the aluminum matrix phase when the Al—Si—Cu alloy is subjected to a heat treatment process that includes an aging heat treatment stage and optionally a solution heat treatment stage. The AlCuMgSi precipitate phase is Al-, Cu-, Mg-, and Si-based, meaning that Al, Cu, Mg, and Si constitute the largest constituents of the precipitate phase by weight. Formation of the AlCuMgSi precipitate phase within the aluminum matrix phase may provide the Al—Si—Cu alloy with high strength at ambient temperature and at elevated temperatures (e.g., up to about 300° C.).
- The amount of iron and manganese in the Al—Si—Cu alloy may be selected to promote the formation of at least one intermetallic phase within the Al—Si—Cu alloy during solidification thereof. In particular, the amount of iron and/or manganese in the Al—Si—Cu alloy may be selected so that at least one intermetallic phase nucleates within the liquid phase aluminum during solidification of the Al—Si—Cu alloy and provides additional nucleation sites (in addition to the nucleation sites provided by the silicon particles) for the subsequent nucleation and equiaxed growth of aluminum dendrites. For example, the at least one intermetallic phase may comprise an Fe-containing intermetallic phase and/or a Mn-containing intermetallic phase. In one specific example, the amount of iron in the Al—Si—Cu alloy may be selected to promote the formation of solid particles of an Al-, Fe-, and Si-based intermetallic (referred to herein as an “AlFeSi intermetallic”) phase within the liquid phase aluminum during solidification of the Al—Si—Cu alloy. The AlFeSi intermetallic phase is Al-, Fe-, and Si-based, meaning that Al, Fe, and Si are the largest constituents of the intermetallic phase. For example, the combined amounts of Al, Fe, and Si in the AlFeSi intermetallic phase may account for, by weight, greater than 50% of the AlFeSi intermetallic phase and, in some cases, greater than 90% of the AlFeSi intermetallic phase.
- In embodiments where the Al—Si—Cu alloy comprises iron, the amount of manganese in the Al—Si—Cu alloy may be selected to promote the formation of an Al-, Fe-, Mn-, and Si-based intermetallic (referred to herein as an “AlFeMnSi intermetallic”) phase within the liquid phase aluminum during solidification of the Al—Si—Cu alloy and to inhibit the formation of an Al-, Fe-, and Si-based intermetallic (referred to herein as an “AlFeSi intermetallic”) phase.
- The hypereutectic Al—Si—Cu alloy does not require addition of scandium (Sc) to achieve an equiaxed grain structure during solidification thereof. As such, the amount of Sc in the Al—Si—Cu alloy may be less than 0.2%, preferably less than 0.05%, and more preferably less than 0.01% by weight of the Al—Si—Cu alloy.
- Additional elements not intentionally introduced into the composition of the Al—Si—Cu alloy nonetheless may be inherently present in the alloy in relatively small amounts, for example, less than 0.2%, preferably less than 0.05%, and more preferably less than 0.01% by weight of the Al—Si—Cu alloy. Such elements may be present, for example, as impurities in the raw materials used to prepare the Al—Si—Cu alloy composition. In embodiments were the Al—Si—Cu alloy is referred to as comprising one or more alloying elements (e.g., one or more of Si, Cu, Mg, Fe, and Mn) and aluminum as balance, the term “as balance” does not exclude the presence of additional elements not intentionally introduced into the composition of the Al—Si—Cu alloy but nonetheless inherently present in the alloy in relatively small amounts, e.g., as impurities.
- In another form, an aluminum alloy composition for manufacturing a three-dimensional high thermal conductivity aluminum alloy part by an additive manufacturing process may comprise, by weight, greater than or equal to 95% aluminum and less than 5% of at least one nucleating agent, and thus may be referred to as a “high-purity Al alloy.” In one specific example, the high-purity Al alloy may comprise, by weight, greater than or equal to 98% aluminum and less than 2% of at least one nucleating agent.
- The at least one nucleating agent included in the high-purity Al alloy may comprise an element or compound that exhibits relatively low solid solubility (e.g., less than 1 wt % or, more preferably, less than 0.5 wt %) in aluminum at temperatures less than 530° C. The composition and amount of the at least one nucleating agent included in the high-purity Al alloy may be selected so that the high-purity Al alloy can be heated to a temperature above a liquidus temperature of the high-purity Al alloy and subsequently cooled to a temperature below a solidus temperature of the high-purity Al alloy to produce an entirely solid polycrystalline high-purity Al alloy that predominantly exhibits an equiaxed grain structure, instead of a columnar grain structure.
- In particular, the composition and amount of the at least one nucleating agent in the high-purity Al alloy may be selected so that, when the high-purity Al alloy is melted and subsequently cooled from an entirely liquid phase to an entirely solid phase, particles of the at least one nucleating agent will form within a solution of liquid phase aluminum prior to formation of a solid aluminum matrix phase. More specifically, when the high-purity Al alloy is heated to a temperature above the liquidus temperature of the high-purity Al alloy and subsequently cooled to a temperature below the liquidus temperature of the high-purity Al alloy, the high-purity Al alloy will transition from an entirely liquid phase to a multiphase system. During this transition, solid particles of the at least one nucleating agent will nucleate throughout a solution of liquid phase aluminum to produce a multiphase system that includes a solution of liquid phase aluminum and a solid phase of particles of the at least one nucleating agent dispersed throughout the liquid phase aluminum. In the multiphase system, the solid particles of the at least one nucleating agent may exhibit a solubility in liquid aluminum of, by weight, less than or equal to 2%, which may help maximize the number if solid particles within the liquid phase aluminum. Nucleation of the solid particles of the at least one nucleating agent may occur simultaneously throughout multiple horizontally and vertically spaced-apart regions of the solution of liquid phase aluminum, and may occur generally homogeneously throughout the solution of liquid phase aluminum. Thereafter, as the high-purity Al alloy continues to cool, solid phase aluminum dendrites will nucleate and grown in multiple directions on the previously formed nuclei (i.e., on the solid particles of the at least one nucleating agent). Growth of these aluminum dendrites within the solidifying high-purity Al alloy will eventually be arrested when neighboring aluminum dendrites impinge upon one another and form grain boundaries. After the high-purity Al alloy has been cooled to a temperature below the solidus temperature of the high-purity Al alloy and is completely solidified, the high-purity Al alloy will exhibit a polycrystalline structure including a continuous aluminum matrix phase and a dispersed phase of particles of the at least one nucleating agent. In addition, the resulting high-purity Al alloy will predominantly include a plurality of randomly oriented equiaxed grains, instead of columnar grains. The equiaxed grains may have a mean diameter in the range of 0.1 μm to 50 μm.
- The high-purity Al alloy may have a liquidus temperature in the range of 660° and 1300° C. and a solidus temperature in the range of 650° and 680° C. As such, the high-purity Al alloy may exhibit a multiphase system of liquid phase aluminum and solid particles of the at least one nucleating agent at a temperature in the range of 650° and 1300° C.
- Due to the relatively low solubility of the at least one nucleating agent in solid aluminum, limited amounts of the at least one nucleating agent will be present in solid solution in the aluminum matrix phase after complete solidification of the high-purity Al alloy. As such, inclusion of the at least one nucleating agent in the high-purity Al alloy will have little to no adverse effect on the thermal conductivity of the high-purity Al alloy. For example, after complete solidification, the high-purity Al alloy may exhibit a thermal conductivity in the range of 120 watts per meter-Kelvin (W/(m·K)) to 220 W/(m·K).
- In some embodiments, the at least one nucleating agent may comprise an element that, when present in the high-purity Al alloy, exhibits a eutectic point or a peritectic point at a concentration of, by weight, less than 5% of the high-purity Al alloy. In such case, the element may be present in the high-purity Al alloy in an amount that is greater than the amount of the same element in the eutectic or peritectic composition of the Al alloy.
- For example, in one form, the at least one nucleating agent may comprise titanium (Ti). A binary Al—Ti alloy exhibits a peritectic point at a composition of, by weight, about 0.12% Ti and a temperature of about 665° C. Therefore, in one form, the high-purity Al alloy may comprise a high-purity Al—Ti alloy including, by weight, greater than or equal to 95% aluminum, greater than 0.12% titanium, and less than 5% titanium. In such case, when this high-purity Al—Ti alloy is melted and subsequently cooled from an entirely liquid phase to an entirely solid phase, solid particles of Al3Ti will nucleate within a solution of liquid phase aluminum at the liquidus temperature of the alloy. Thereafter, aluminum dendrites will nucleate and grown in all directions on the previously formed Al3Ti particles, resulting in the formation of a polycrystalline structure that predominantly includes a plurality of randomly oriented equiaxed grains, instead of columnar grains.
- Some examples of elements (in addition to Ti) that can be used as the at least one nucleating agent in the high-purity Al alloy include boron (B), beryllium (Be), cobalt (Co), chromium (Cr), cesium (Cs), iron (Fe), hafnium (Hf), manganese (Mn), molybdenum (Mo), niobium (Nb), lead (Pb), sulfur (S), zirconium (Zr), antimony (Sb), scandium (Sc), selenium (Se), strontium (Sr), tantalum (Ta), vanadium (V), tungsten (W), and combinations thereof. For example, the high-purity Al alloy may include, by weight, equal to or greater than 0% B to 5% B, 0.7-5% Be, 0.9-5% Co, 0.3-5% Cr, equal to or greater than 0% Cs to 5% Cs, 1.7-5% Fe, 0.4-5% Hf, 1.8-5% Mn, equal to or greater than 0% Mo to 5% Mo, equal to or greater than 0% Nb to 5% Nb, 1.4-5% Pb, equal to or greater than 0% S to 5% S, 0.9-5% Sb, 0.4-5% Sc, equal to or greater than 0% Se to 5% Se, 0.5-5% Sr, equal to or greater than 0% Ta to 5% Ta, 0.12-5% Ti, equal to or greater than 0% V to 5% V, equal to or greater than 0% W to 5% W, and/or equal to or greater than 0% Zr to 5% Zr, and the balance Al.
- The high-purity Al alloy may include one or more additional elements that may or may not be intentionally introduced into the composition of the high-purity Al alloy, with such additional elements being present in the high-purity Al alloy in amounts less than 0.2%, preferably less than 0.05%, and more preferably less than 0.01% by weight of the high-purity Al alloy. Additional elements not intentionally introduced into the composition of the high-purity Al alloy may be present, for example, as impurities in the raw materials used to prepare the high-purity Al alloy composition. In embodiments were the high-purity Al alloy is referred to as comprising at least one nucleating agent (e.g., at least one element or compound of Ti, B, Be, Co, Cr, Cs, Fe, Hf, Mn, Mo, Nb, Pb, S, Zr, Sb, Sc, Se, Sr, Ta, V, or W) and aluminum as balance, the term “as balance” does not exclude the presence of additional elements not intentionally introduced into the composition of the high-purity Al alloy but nonetheless inherently present in the alloy in relatively small amounts, e.g., as impurities.
-
FIG. 2 depicts anapparatus 100 that can be used to manufacture a three-dimensionalaluminum alloy part 108 from an aluminum alloypowder feed material 110, which may comprise or consist of the Al—Si—Cu alloy and/or the high-purity Al alloy. The three-dimensionalaluminum alloy part 108 may be formed via a powder bed fusion additive manufacturing process, in which digital design data is used to build up thepart 108 layer by layer. For example, theapparatus 100 may be configured to manufacture thealuminum alloy part 108 by a powder bed fusion process, which may be carried out using a selective laser melting or an electron beam melting technique. In such case, theapparatus 100 may comprise abuilding chamber 112 including abuilding platform 114, a powderfeed material reservoir 116 separated from thebuilding chamber 112 by aweir 118, and a high-powerenergy beam source 120. - A volume of the aluminum alloy
powder feed material 110 may be distributed over a surface of thebuilding platform 114, for example, by ablade 122 to form alayer 124 of aluminum alloypowder feed material 110. In one form, the aluminum alloypowder feed material 110 may have a mean particle diameter in the range of 5 micrometers to 100 micrometers and thelayer 124 of aluminum alloypowder feed material 110 may have a thickness in the range of 20 micrometers to 100 micrometers. InFIG. 2 , thelayer 124 ofpowder feed material 110 is distributed over a surface of thebuilding platform 114 and also over a surface of one or more previously melted, fused, and solidified aluminum alloy layers 126 (FIG. 3 ). Then,selective regions 128 of thelayer 124 are scanned by a high-energy laser orelectron beam 130. As shown, theselective regions 128 of thelayer 124 scanned by thebeam 130 correspond to a cross-section of the three-dimensionalaluminum alloy part 108 being formed. - Referring now to
FIG. 4 , as the high-energy beam 130 scans theselective regions 128 of thelayer 124, thebeam 130 impinges thelayer 124 and heat generated by absorption of energy from thebeam 130 initiates melting of thelayer 124 within theselective regions 128. As a result, a pool of moltenaluminum alloy material 132 is created that fully penetrates thelayer 124 and extends through thelayer 124 in a direction substantially perpendicular to the surface of the building platform 114 (i.e., along the z-axis). In one form, the pool of moltenaluminum alloy material 132 may extend into thelayer 124 and partially into theunderlying layers 126 at a depth in the range of 10 μm to 300 μm. After termination of the high-energy beam 130, the pool of moltenaluminum alloy material 132 rapidly cools and solidifies to form another solidified aluminum alloy layer that bonds with the previously solidified layers 126. For example, after termination of the high-energy beam 130, the pool of moltenaluminum alloy material 132 may cool at a rate in the range of 104 Kelvin per second to 106 Kelvin per second. Thereafter, thereservoir 116 may be raised in a build direction (i.e., along the z-axis), or thebuilding platform 114 may be lowered, by a thickness of the newly solidified layer, for example, by a piston 134. Then, a further layer ofpowder feed material 110 may be distributed over the surface of thebuilding platform 114 and over the previously solidified aluminum alloy layers 126, scanned with the high-energy beam 130 in regions corresponding to another cross-section of the three-dimensionalaluminum alloy part 108, and solidified to form yet another solidified aluminum alloy layer that bonds with the previously solidified layers 126. This process is repeated until theentire alloy part 108 is built up layer-by-layer. - In embodiments where the aluminum alloy
powder feed material 110 comprises the Al—Si—Cu alloy, the resultingalloy part 108 may be heat treated to dissolve into solid solution any coarse intermetallic phases that may have formed during solidification and/or to promote the formation of one or more Cu-containing precipitate phases (e.g., an AlCu precipitate phase and/or AlCuMgSi precipitate phase) within the aluminum matrix phase. The heat treatment process may include an aging heat treatment stage and optionally a solution heat treatment stage. If performed, the solution heat treatment stage may be performed prior to the aging heat treatment stage. During the optional solution heat treatment stage, thealloy part 108 may be heated to a temperature in the range of 490° C. to 550° C. for a duration of 10 minutes to 10 hours. In one form, thealloy part 108 may be heated during the solution heat treatment stage to a temperature in the range of 490° C. to 550° C. for a duration of 3 hours to 10 hours. In another form, thealloy part 108 may be heated during the solution heat treatment stage to a temperature in the range of 490° C. to 550° C. for a duration of less than 1 hours, for example, for a duration of 10 minutes to 30 minutes. After the optional solution heat treatment stage, thealloy part 108 may be cooled or quenched to a temperature less than 100° C., e.g., ambient temperature, at a cooling rate sufficient to prevent diffusion and precipitation of alloying elements dissolved in into solid solution during the solution heat treatment stage. In the aging heat treatment stage, thealloy part 108 may be heated to a temperature in the range of 180° C. to 210° C. for a duration of 0.5 hours to 7 hours. After the aging heat treatment stage, thealloy part 108 may be cooled or quenched to a temperature less than 100° C., e.g., ambient temperature. - As described in further detail above, the Al—Si—Cu alloy and the high-purity Al alloy each include at least one element or compound that, during solidification of the alloy, nucleates within a solution of liquid phase aluminum and provides sites for the subsequent nucleation and growth of aluminum dendrites. However, referring now to
FIGS. 5 and 6 , it has been found that, when aluminum alloys that do not include such elements and/or compounds (or do not include appropriate amounts of such elements and/or compounds) are melted and subsequently solidified, columnar-shapedaluminum dendrites 236 tend to grow unidirectionally within the solidifying aluminum alloys and in epitaxy with a surface of an adjacent solid substrate 238 (FIG. 5 ). As shown inFIG. 6 , after solidification, the resulting aluminum alloys exhibit a columnar grain structure including a plurality of unidirectionalcolumnar grains 240. Likewise, it has been found that, when such aluminum alloys are used as a powder feed material in an additive manufacturing process, such as the process described above with respect toFIGS. 2-4 , columnar-shaped aluminum dendrites tend to grow unidirectionally in the build direction (i.e., along the z-axis) and in epitaxy with the surface of thebuilding platform 114 or with the surface of one or more previously solidified aluminum alloy layers 126. In addition, this unidirectional epitaxial aluminum dendrite growth tends to persist through each of the subsequently melted and solidified layers of the aluminum alloy part being formed, with the resulting aluminum alloy part being readily susceptible to the formation of cracks along the grain boundaries between the adjacent elongatedcolumnar grains 240. - As shown in
FIGS. 7 and 8 , when the Al—Si—Cu alloy and the high-purity Al alloy are melted and subsequently cooled, solidification of the alloys begins with the nucleation ofsolid particles 342 throughout a solution ofliquid phase aluminum 344. In the Al—Si—Cu alloy, thesolid particles 342 may comprise particles of substantially pure silicon and optionally particles of an Fe- and/or Mn-containing intermetallic phase. Alternatively, in the high-purity Al alloy, thesolid particles 342 may comprise an element or compound of Ti, B, Be, Co, Cr, Cs, Fe, Hf, Mn, Mo, Nb, Pb, S, Zr, Sb, Sc, Se, Sr, Ta, and/or V, as described above in further detail. As these alloys continue to solidify, solidphase aluminum dendrites 346 will nucleate and grown in all directions on thesolid particles 342, as shown inFIG. 7 .Additional aluminum dendrites 347 also may grow in epitaxy with a surface of anadjacent substrate 338. Growth of thealuminum dendrites liquid phase aluminum 344 will eventually be arrested when neighboringaluminum dendrites form grain boundaries 348, as shown inFIG. 8 . The resulting aluminum alloys will exhibit an equiaxed grain structure including a plurality of randomly orientedequiaxed grains 350. Likewise, when the Al—Si—Cu alloy and/or the high-purity Al alloy are prepared in powder form and used as a powder feed material in an additive manufacturing process, such as the process described above with respect toFIGS. 2-4 ,aluminum dendrite 346 growth has been found to occur heterogeneously throughout each layer of solidifying aluminum alloy material. In addition, any columnar-shapedaluminum dendrites 347 originating on (e.g., growing in epitaxy with) the surface of thebuilding platform 114 or on the surface of one or more previously solidified aluminum alloy layers 126 are stopped by thealuminum dendrites 346 growing in multiple random directions from thesolid particles 342 distributed throughout the bulk of each layer of solidifying aluminum alloy material. - The above description of preferred exemplary embodiments, aspects, and specific examples are merely descriptive in nature; they are not intended to limit the scope of the claims that follow. Each of the terms used in the appended claims should be given its ordinary and customary meaning unless specifically and unambiguously stated otherwise in the specification.
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US11286543B2 (en) | 2017-02-01 | 2022-03-29 | Hrl Laboratories, Llc | Aluminum alloy components from additive manufacturing |
US11578389B2 (en) | 2017-02-01 | 2023-02-14 | Hrl Laboratories, Llc | Aluminum alloy feedstocks for additive manufacturing |
US11674204B2 (en) | 2017-02-01 | 2023-06-13 | Hrl Laboratories, Llc | Aluminum alloy feedstocks for additive manufacturing |
US20210111005A1 (en) * | 2019-10-15 | 2021-04-15 | Tokyo Electron Limited | Member, manufacturing method of member and substrate processing apparatus |
CN114226736A (en) * | 2021-12-21 | 2022-03-25 | 北京航空航天大学 | Method for inhibiting crack formation and promoting grain refinement of additive manufacturing aluminum alloy |
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DE102019106979A1 (en) | 2019-09-26 |
CN110293225A (en) | 2019-10-01 |
CN110293225B (en) | 2022-03-01 |
DE102019106979B4 (en) | 2024-01-11 |
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