Processability of A6061 Aluminum Alloy Using Laser Powder Bed Fusion by In Situ Synthesis of Grain Refiners

Author:

Rosito Michele1ORCID,Vanzetti Matteo12ORCID,Padovano Elisa1,Gili Flavia3,Sampieri Roberta4,Bondioli Federica15ORCID,Badini Claudio Francesco1

Affiliation:

1. Department of Applied Science and Technology, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Turin, Italy

2. Center for Sustainable Future Technologies IIT@Polito, Istituto Italiano di Tecnologia, Via Livorno 60, 10124 Torino, Italy

3. Centro Ricerche Fiat S.c.p.A. (CRF) Stellantis, Corso Settembrini 40, Corpo 1, Ingresso 109/A, 10135 Torino, Italy

4. Stellantis, Via Biscaretti di Ruffia 90/A, 10135 Torino, Italy

5. Consorzio Interuniversitario Nazionale per la Scienza e Tecnologia dei Materiali (INSTM), Via G. Giusti 9, 50121 Firenze, Italy

Abstract

Despite the increasing interest in laser powder bed fusion (LPBF), only a few cast aluminum alloys are available for this process. This study focuses on improving the LPBF processability of the A6061 alloy, which is challenging due to its wide solidification range, the dendritic columnar grain growth, and consequent solidification cracking. To address these issues, in situ-synthesized grain refiners can be used to induce equiaxial grain growth and prevent crack formation. A6061 RAM2 powder—a mixture of A6061, Ti, and B4C—was characterized and processed using a low-power LPBF machine to create an in situ particle-reinforced metal matrix composite. Parameter optimization was performed to evaluate the effect of their variation on the printability of the alloy. Microstructural characterization of the samples revealed that the complete reaction and the synthesis of the ceramic reinforcement did not occur. However, TiAl3 was synthesized during the process and promoted a partial grain refinement, leading to the formation of equiaxial grains and preventing the formation of solidification cracks. The tensile tests carried out on the optimized samples exhibit superior mechanical properties compared to those of A6061 processed through LPBF.

Publisher

MDPI AG

Subject

General Materials Science,Metals and Alloys

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