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A review of laser powder bed fusion additive manufacturing of aluminium alloys : microstructure and properties

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Kotadia, H. R., Gibbons, Gregory John, Das, A. and Howes, P. D. (2021) A review of laser powder bed fusion additive manufacturing of aluminium alloys : microstructure and properties. Additive Manufacturing, 46 . 102155. doi:10.1016/j.addma.2021.102155

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Official URL: http://dx.doi.org/10.1016/j.addma.2021.102155

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Abstract

Additive manufacturing (AM) of metallic alloys for structural and functional applications has attracted significant interest in the last two decades as it brings a step change in the philosophy of design and manufacturing. The ability to design and fabricate complex geometries not amenable to conventional manufacturing, and the potential to reduce component weight without compromising performance, is particularly attractive for aerospace and automotive applications. This has culminated in rapid progress in AM with Ti- and Ni-based alloys. In contrast, the development of AM with Al-alloys has been slow, despite their widespread adoption in industry owing to an excellent combination of low density and high strength-to-weight ratio. Research to date has focused on castable and weldable AlSiMg-based alloys (which are less desirable for demanding structural applications), as well as on the development of new AM-specific AlMgSc alloys (based on 5xxx series). However, high strength wrought Al-alloys have typically been unsuitable for AM due to their unfavourable microstructural characteristics under rapid directional solidification conditions. Nevertheless, recent research has shown that there is promise in overcoming the associated challenges. Herein, we present a review of the current status of AM with Al-alloys. We primarily focus on the microstructural characteristics, and on exploring how these influence mechanical properties. The current metallurgical understanding of microstructure and defect formation in Al-alloys during AM is discussed, along with recent promising research exploring various microstructural modification methodologies. Finally, the remaining challenges in the development of AM with high-strength Al-alloys are discussed.

Item Type: Journal Article
Subjects: T Technology > TA Engineering (General). Civil engineering (General)
T Technology > TN Mining engineering. Metallurgy
T Technology > TS Manufactures
Divisions: Faculty of Science, Engineering and Medicine > Engineering > WMG (Formerly the Warwick Manufacturing Group)
Library of Congress Subject Headings (LCSH): Additive manufacturing , Aluminum, Aluminum alloys -- Mechanical properties, Aluminum alloys -- Microstructure, Powder metallurgy -- Industrial applications, Lasers -- Industrial applications
Journal or Publication Title: Additive Manufacturing
Publisher: Elsevier
ISSN: 2214-8604
Official Date: October 2021
Dates:
DateEvent
October 2021Published
13 July 2021Available
28 June 2021Accepted
Volume: 46
Article Number: 102155
DOI: 10.1016/j.addma.2021.102155
Status: Peer Reviewed
Publication Status: Published
Access rights to Published version: Restricted or Subscription Access
RIOXX Funder/Project Grant:
Project/Grant IDRIOXX Funder NameFunder ID
UNSPECIFIEDWarwick Manufacturing Grouphttp://viaf.org/viaf/123628346
105613Innovate UKhttp://dx.doi.org/10.13039/501100006041
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