Effect of Zr and Sc additions on coarsening- and creep resistance of AlSi10Mg fabricated by laser powder bed fusion

Coello, Ismael E.; Glerum, Jennifer A.; Ekaputra, Clement N.; Mogonye, Jon-Erik; Dunand, David C.

doi:10.1016/j.addma.2025.104707

Effect of Zr and Sc additions on coarsening- and creep resistance of AlSi10Mg fabricated by laser powder bed fusion

Journal Article · Mon Feb 17 00:00:00 EST 2025 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2025.104707· OSTI ID:2537975

Coello, Ismael E. ^[1]; ^[2]; ^[1]; ^[3]; Dunand, David C. ^[1]

Northwestern University, Evanston, IL (United States)
Northwestern University, Evanston, IL (United States); Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)
US. Army Combat Capabilities Development Command, Army Research Laboratory, Aberdeen Proving Ground, MD (United States)

Microstructure and creep properties are studied in a eutectic AlSi10Mg alloy modified with Zr and Sc additions (Al-9.8Si-0.32Mg-0.70Zr-0.23Sc, wt%) manufactured through laser powder-bed fusion (L-PBF). Three types of Zr/Sc-bearing powders - elemental, master-alloy, and pre-alloyed - are employed in the fabrication process, with the pre-alloyed powders providing the highest incorporation of Zr and Sc in the Al matrix. Here, the as-printed alloy exhibits a fine cellular Al-Si eutectic structure which fragments and coarsens into micron-sized Si particles during aging at 300 ºC, leading to a steady drop in alloy microhardness between 0.1 and 1000 h. Coarsening of the eutectic Si phase during aging is not measurably affected by Zr and Sc in solid solution, which precipitate during aging and increases strength, compensating weakening from Si coarsening between 1 and 200 h at 300 ºC. Atom-probe analysis in the peak-aged condition (96 h/300 °C) confirms the presence of Al₃(Sc,Zr) secondary nano-precipitates with an average radius of 1.0 nm and some Si solubility. Micron-sized grains are present throughout the alloy, with ultra-fine-grained regions at the melt pool boundaries, neither of which coarsen during long-term aging at 300 ºC. Under creep conditions at 300 °C, the Zr/Sc-bearing alloy with Al₃(Sc,Zr) nano-precipitates exhibits power-law behavior, with a high apparent stress exponent (n_a = 9) and a high threshold stress (σ_th = 43 MPa), exhibiting nearly double the strength of a Zr/Sc-free AlSi10Mg control alloy (σ_th = 22 MPa).

View Accepted Manuscript (DOE)

Research Organization:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Organization:: National Science Foundation (NSF); US Army Research Laboratory (USARL); US Department of the Navy, Office of Naval Research (ONR); USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: AC52-07NA27344

OSTI ID:: 2537975

Report Number(s):: LLNL--JRNL-868147; 1103814

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Vol. 101; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Effect of Zr and Sc additions on coarsening- and creep resistance of AlSi10Mg fabricated by laser powder bed fusion

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