Microstructure analysis and machinability of additively manufactured A205 aluminum with heat treatments

Randolph, Otto; Zvanut, Ryan; Tai, Bruce L.

doi:10.1016/j.jmapro.2024.07.111

Microstructure analysis and machinability of additively manufactured A205 aluminum with heat treatments

Journal Article · Sat Aug 03 00:00:00 EDT 2024 · Journal of Manufacturing Processes

DOI:https://doi.org/10.1016/j.jmapro.2024.07.111· OSTI ID:2462681

Randolph, Otto ^[1]; Zvanut, Ryan ^[2]; Tai, Bruce L. ^[1]

Texas A & M Univ., College Station, TX (United States)
Kansas City Nuclear Security Campus (KCNSC), Kansas City, MO (United States)

A205 aluminum is one of the few high-strength aluminum alloys discovered for additive manufacturing (AM). The microstructure and heat treatment effects of AM A205 vary from those of its cast form, indicating possible differences in machinability during post-processing. Here, the objective of this research is to determine these variations of AM A205 and their effects on machinability using the cast condition as the baseline. As built and two heat-treated conditions (solution treatment and age hardening) were applied and compared in terms of their microstructures, micro-hardness, and machinability including vibration, specific cutting energy, chip morphology, and surface finish. The effects of print orientations on machinability were tested as well and found to be insignificant. AM as built had a higher hardness and slightly better machinability than its cast as built cast counterpart due to a smaller grain size (1 µm vs. 15 µm), eutectic θ-Al₂Cu lattice and a fine, homogeneous TiB₂ distribution. The solution treatment dissolved this θ-Al₂Cu lattice and increased the grain size (3 µm) which decreased the hardness, increased the ductility seen in the chips, and reduced the overall machinability. The presence of θ’-Al₂Cu precipitates improved the machinability of aged AM A205. In addition, it was found that A205 exhibited both ductile and brittle behavior depending on the cutting speed, thus producing different machinability. The speed dependency is related to the material condition and heat treatment.

View Accepted Manuscript (DOE)

Research Organization:: Kansas City Nuclear Security Campus (KCNSC), Kansas City, MO (United States)

Sponsoring Organization:: USDOE; USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: NA0002839

OSTI ID:: 2462681

Alternate ID(s):: OSTI ID: 2427421

Report Number(s):: NSC--614-6387

Journal Information:: Journal of Manufacturing Processes, Journal Name: Journal of Manufacturing Processes Vol. 127; ISSN 1526-6125

Publisher:: Society of Manufacturing Engineers; ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
42 ENGINEERING
A205 aluminum
Additive manufacturing
Heat treatment
Machinability
Microstructure

Microstructure analysis and machinability of additively manufactured A205 aluminum with heat treatments

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