Microstructural evolution and strengthening mechanisms in a heat-treated additively manufactured Al–Cu–Mn–Zr alloy

Michi, Richard A.; Sisco, Kevin D.; Bahl, Sumit; Allard, Jr., Lawrence R.; Wagner, Karla; Poplawsky, Jonathan D.; Leonard, Donovan N.; Dehoff, Ryan R.; Plotkowski, Alex J.; Shyam, Amit

doi:10.1016/j.msea.2022.142928

Title: Microstructural evolution and strengthening mechanisms in a heat-treated additively manufactured Al–Cu–Mn–Zr alloy

Abstract

In this report the microstructural and strength evolution of an additively manufactured Al-8.6Cu-0.5Mn-0.9Zr alloy upon aging at 300, 350, and 400 °C is investigated. The strengthening phases of the alloy evolve significantly upon aging, with breakdown and spheroidization of the interconnected θ-Al₂Cu network, dissolution of metastable θ'-Al₂Cu precipitates, and precipitation of nanometric L1₂-Al₃Zr from a matrix supersaturated in Zr. In the peak-aged states, the alloy displays a favorable combination of strength and ductility, with a room-temperature yield strength of 314–341 MPa and ductility of 11–13%. The measured yield strengths for microstructures with different aging treatments are compared to predictions of yield strengths from grain boundary, solid solution, and particle strengthening contributions. The observed strain hardening behavior is related to fundamental precipitate and dislocation interactions. Comparison between predicted and measured strength values indicates a continued need for strengthening models specifically developed for the heterogeneous microstructures of additively manufactured alloys.

Authors:

Michi, Richard A. ^[1]; Sisco, Kevin D. ^[2]; Bahl, Sumit ^[1];

^[1];

^[3];

^[1];

^[1]

Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Univ. of Tennessee, Knoxville, TN (United States)
Georgia Institute of Technology, Atlanta, GA (United States)

Publication Date:: Fri Mar 04 00:00:00 EST 2022

Research Org.:: Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

Sponsoring Org.:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Transportation Office. Vehicle Technologies Office; USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing Office

OSTI Identifier:: 1855664

Grant/Contract Number:: AC05-00OR22725

Resource Type:: Accepted Manuscript

Journal Name:: Materials Science and Engineering. A, Structural Materials: Properties, Microstructure and Processing

Additional Journal Information:: Journal Volume: 840; Journal Issue: N/A; Journal ID: ISSN 0921-5093

Publisher:: Elsevier

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE; additive manufacturing; aluminum alloys; Al–Cu–Mn–Zr alloy; strengthening mechanisms; strain hardening

Citation Formats


                    Michi, Richard A., Sisco, Kevin D., Bahl, Sumit, Allard, Jr., Lawrence R., Wagner, Karla, Poplawsky, Jonathan D., Leonard, Donovan N., Dehoff, Ryan R., Plotkowski, Alex J., and Shyam, Amit. Microstructural evolution and strengthening mechanisms in a heat-treated additively manufactured Al–Cu–Mn–Zr alloy.  United States: N. p., 2022. 
Web.  doi:10.1016/j.msea.2022.142928.

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                    Michi, Richard A., Sisco, Kevin D., Bahl, Sumit, Allard, Jr., Lawrence R., Wagner, Karla, Poplawsky, Jonathan D., Leonard, Donovan N., Dehoff, Ryan R., Plotkowski, Alex J., & Shyam, Amit. Microstructural evolution and strengthening mechanisms in a heat-treated additively manufactured Al–Cu–Mn–Zr alloy.  United States.  https://doi.org/10.1016/j.msea.2022.142928

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                    Michi, Richard A., Sisco, Kevin D., Bahl, Sumit, Allard, Jr., Lawrence R., Wagner, Karla, Poplawsky, Jonathan D., Leonard, Donovan N., Dehoff, Ryan R., Plotkowski, Alex J., and Shyam, Amit. Fri .  
"Microstructural evolution and strengthening mechanisms in a heat-treated additively manufactured Al–Cu–Mn–Zr alloy".  United States.  https://doi.org/10.1016/j.msea.2022.142928.  https://www.osti.gov/servlets/purl/1855664.

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@article{osti_1855664,

  title        = {Microstructural evolution and strengthening mechanisms in a heat-treated additively manufactured Al–Cu–Mn–Zr alloy},

  author       = {Michi, Richard A. and Sisco, Kevin D. and Bahl, Sumit and Allard, Jr., Lawrence R. and Wagner, Karla and Poplawsky, Jonathan D. and Leonard, Donovan N. and Dehoff, Ryan R. and Plotkowski, Alex J. and Shyam, Amit},

  abstractNote = {In this report the microstructural and strength evolution of an additively manufactured Al-8.6Cu-0.5Mn-0.9Zr alloy upon aging at 300, 350, and 400 °C is investigated. The strengthening phases of the alloy evolve significantly upon aging, with breakdown and spheroidization of the interconnected θ-Al2Cu network, dissolution of metastable θ'-Al2Cu precipitates, and precipitation of nanometric L12-Al3Zr from a matrix supersaturated in Zr. In the peak-aged states, the alloy displays a favorable combination of strength and ductility, with a room-temperature yield strength of 314–341 MPa and ductility of 11–13%. The measured yield strengths for microstructures with different aging treatments are compared to predictions of yield strengths from grain boundary, solid solution, and particle strengthening contributions. The observed strain hardening behavior is related to fundamental precipitate and dislocation interactions. Comparison between predicted and measured strength values indicates a continued need for strengthening models specifically developed for the heterogeneous microstructures of additively manufactured alloys.},

  doi          = {10.1016/j.msea.2022.142928},

  journal      = {Materials Science and Engineering. A, Structural Materials: Properties, Microstructure and Processing},

  number       = N/A,

  volume       = 840,

  place        = {United States},

  year         = {Fri Mar 04 00:00:00 EST 2022},

  month        = {Fri Mar 04 00:00:00 EST 2022}

}

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Title: Microstructural evolution and strengthening mechanisms in a heat-treated additively manufactured Al–Cu–Mn–Zr alloy

Abstract

Citation Formats

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Stability and elastic properties of L12-(Al,Cu)3(Ti,Zr) phases: Ab initio calculations and experiments journal, January 2007

Sequential modeling of local precipitation, strength and strain hardening in friction stir welds of an aluminum alloy 6005A-T6 journal, October 2007

Mechanisms for stabilizing θ′(Al2Cu) precipitates at elevated temperatures investigated with phase field modeling journal, June 2019

Precipitation evolution in Al–Zr and Al–Zr–Ti alloys during isothermal aging at 375–425°C journal, January 2008

Microstructure and mechanical properties of Al-Cu alloys fabricated by selective laser melting of powder mixtures journal, February 2018

Multiscale modelling of precipitation hardening in Al–Cu alloys: Dislocation dynamics simulations and experimental validation journal, April 2020

Interface-mediated plasticity of nanoscale Al–Al2Cu eutectics journal, March 2020

Structural refinement and nanomechanical response of laser remelted Al-Al2Cu lamellar eutectic journal, October 2017

The influence of precipitation on plastic deformation of Al–Cu–Li alloys journal, June 2013

First-principles studies on lattice constants and local lattice distortions in solid solution aluminum alloys journal, February 2013

An analysis of the influence of the precipitate type on the mechanical behavior of Al - Cu alloys by means of micropillar compression tests journal, August 2020

Strengthening mechanisms in aluminum containing coherent Al3Sc precipitates and incoherent Al2O3 dispersoids journal, February 2007

Precipitation hardening journal, December 1985

On the stability of orowan loops around coherent spherical ordered precipitates journal, September 1989

3D printing of high-strength aluminium alloys journal, September 2017

Effect of copper content on the tensile elongation of Al–Cu–Mn–Zr alloys: Experiments and finite element simulations journal, January 2020

The synergistic role of Mn and Zr/Ti in producing θ′/L12 co-precipitates in Al-Cu alloys journal, August 2020

Influence on microstructure, strength and ductility of build platform temperature during laser powder bed fusion of AlSi10Mg journal, December 2020

Analysis of Three-dimensional Atom-probe Data by the Proximity Histogram journal, September 2000

Precipitation kinetics, microstructure evolution and mechanical behavior of a developed Al–Mn–Sc alloy fabricated by selective laser melting journal, July 2020

Criteria for developing castable, creep-resistant aluminum-based alloys – A review journal, March 2006

Strengthening mechanisms of high-performance Al-Mn-Mg-Sc-Zr alloy fabricated by selective laser melting journal, July 2021

A review of selective laser melting of aluminum alloys: Processing, microstructure, property and developing trends journal, February 2019

Grain refinement and crack inhibition of selective laser melted AA2024 aluminum alloy via inoculation with TiC–TiH2 journal, May 2021

Aging behavior and strengthening mechanisms of coarsening resistant metastable θ' precipitates in an Al–Cu alloy journal, January 2021

Plasticity of laser-processed nanoscale Al Al2Cu eutectic alloy journal, September 2018

Microstructure-based modelling of isotropic and kinematic strain hardening in a precipitation-hardened aluminium alloy journal, May 2011

Microstructural features of Sc- and Zr-modified Al-Mg alloys processed by selective laser melting journal, February 2017

Fusion-Based Additive Manufacturing for Processing Aluminum Alloys: State-of-the-Art and Challenges: Fusion-Based Additive Manufacturing for Processing Aluminum Alloys journal, April 2017

Laser powder bed fusion of nano-CaB6 decorated 2024 aluminum alloy journal, May 2021

Modeling the effect of Al3Sc precipitates on the yield stress and work hardening of an Al–Mg–Sc alloy journal, May 2008

The effect of shear-resistant, plate-shaped precipitates on the work hardening of Al alloys: Towards a prediction of the strength–elongation correlation journal, December 2009

3D printing of Aluminium alloys: Additive Manufacturing of Aluminium alloys using selective laser melting journal, December 2019

A solution to the hot cracking problem for aluminium alloys manufactured by laser beam melting journal, September 2020

A Threshold Selection Method from Gray-Level Histograms journal, January 1979

Back pressure equal channel angular consolidation of pure Al particles journal, December 2005

New Aluminum Alloys Specifically Designed for Laser Powder Bed Fusion: A Review journal, March 2019

A review on selective laser sintering/melting (SLS/SLM) of aluminium alloy powders: Processing, microstructure, and properties journal, October 2015

Physics and phenomenology of strain hardening: the FCC case journal, January 2003

Predicting slip behavior in alloys containing shearable and strong particles journal, September 1993

Changing the alloy composition of Al7075 for better processability by selective laser melting journal, December 2016

Elevated temperature microstructural stability in cast AlCuMnZr alloys through solute segregation
journal, September 2019

On the Estimation of True Hall-Petch Constants and Their Role on the Superposition Law Exponent in Al Alloys
journal, August 2012

Distribution of plastic strain in alloys containing small particles
journal, June 1975

Tracking the path of dislocations across ordered Al3Zr nano-precipitates in three dimensions
journal, January 2014

Design approaches for printability-performance synergy in Al alloys for laser-powder bed additive manufacturing
journal, June 2021

Microstructure and mechanical properties of Al-Mg-Zr alloys processed by selective laser melting
journal, July 2018

Selective laser melting of a high strength Al Mn Sc alloy: Alloy design and strengthening mechanisms
journal, June 2019

On the strength of discontinuous silicon carbide reinforced aluminum composites
journal, January 1986

Six decades of the Hall–Petch effect – a survey of grain-size strengthening studies on pure metals
journal, June 2016

Ambient- and elevated-temperature strengthening by Al3Zr-Nanoprecipitates and Al3Ni-Microfibers in a cast Al-2.9Ni-0.11Zr-0.02Si-0.005Er (at.%) alloy
journal, June 2019

Additive manufacturing of metallic components – Process, structure and properties
journal, March 2018

Unveiling damage sites and fracture path in laser powder bed fusion AlSi10Mg: Comparison between horizontal and vertical loading directions
journal, March 2021

Strategies for fabricating atom probe specimens with a dual beam FIB
journal, March 2005

Microstructure and properties of additively manufactured Al–Ce–Mg alloys
journal, March 2021

Strengthening of an Al–Cu–Sn alloy by deformation-resistant precipitate plates
journal, August 2008

SLM-processed Sc- and Zr- modified Al-Mg alloy: Mechanical properties and microstructural effects of heat treatment
journal, July 2017

Strengthening mechanisms in Al Ni Sc alloys containing Al3Ni microfibers and Al3Sc nanoprecipitates
journal, February 2019

Additive manufacturing of metals
journal, September 2016

Stability and elastic properties of L12-(Al,Cu)3(Ti,Zr) phases: Ab initio calculations and experiments
journal, January 2007

Sequential modeling of local precipitation, strength and strain hardening in friction stir welds of an aluminum alloy 6005A-T6
journal, October 2007

Mechanisms for stabilizing θ′(Al2Cu) precipitates at elevated temperatures investigated with phase field modeling
journal, June 2019

Precipitation evolution in Al–Zr and Al–Zr–Ti alloys during isothermal aging at 375–425°C
journal, January 2008

Microstructure and mechanical properties of Al-Cu alloys fabricated by selective laser melting of powder mixtures
journal, February 2018

Multiscale modelling of precipitation hardening in Al–Cu alloys: Dislocation dynamics simulations and experimental validation
journal, April 2020

Interface-mediated plasticity of nanoscale Al–Al2Cu eutectics
journal, March 2020

Structural refinement and nanomechanical response of laser remelted Al-Al2Cu lamellar eutectic
journal, October 2017

The influence of precipitation on plastic deformation of Al–Cu–Li alloys
journal, June 2013

First-principles studies on lattice constants and local lattice distortions in solid solution aluminum alloys
journal, February 2013

An analysis of the influence of the precipitate type on the mechanical behavior of Al - Cu alloys by means of micropillar compression tests
journal, August 2020

Strengthening mechanisms in aluminum containing coherent Al3Sc precipitates and incoherent Al2O3 dispersoids
journal, February 2007

Precipitation hardening
journal, December 1985

On the stability of orowan loops around coherent spherical ordered precipitates
journal, September 1989

3D printing of high-strength aluminium alloys
journal, September 2017

Effect of copper content on the tensile elongation of Al–Cu–Mn–Zr alloys: Experiments and finite element simulations
journal, January 2020

The synergistic role of Mn and Zr/Ti in producing θ′/L12 co-precipitates in Al-Cu alloys
journal, August 2020

Influence on microstructure, strength and ductility of build platform temperature during laser powder bed fusion of AlSi10Mg
journal, December 2020

Analysis of Three-dimensional Atom-probe Data by the Proximity Histogram
journal, September 2000

Precipitation kinetics, microstructure evolution and mechanical behavior of a developed Al–Mn–Sc alloy fabricated by selective laser melting
journal, July 2020

Criteria for developing castable, creep-resistant aluminum-based alloys – A review
journal, March 2006

Strengthening mechanisms of high-performance Al-Mn-Mg-Sc-Zr alloy fabricated by selective laser melting
journal, July 2021

A review of selective laser melting of aluminum alloys: Processing, microstructure, property and developing trends
journal, February 2019

Grain refinement and crack inhibition of selective laser melted AA2024 aluminum alloy via inoculation with TiC–TiH2
journal, May 2021

Aging behavior and strengthening mechanisms of coarsening resistant metastable θ' precipitates in an Al–Cu alloy
journal, January 2021

Plasticity of laser-processed nanoscale Al Al2Cu eutectic alloy
journal, September 2018

Microstructure-based modelling of isotropic and kinematic strain hardening in a precipitation-hardened aluminium alloy
journal, May 2011

Microstructural features of Sc- and Zr-modified Al-Mg alloys processed by selective laser melting
journal, February 2017

Fusion-Based Additive Manufacturing for Processing Aluminum Alloys: State-of-the-Art and Challenges: Fusion-Based Additive Manufacturing for Processing Aluminum Alloys
journal, April 2017

Laser powder bed fusion of nano-CaB6 decorated 2024 aluminum alloy
journal, May 2021

Modeling the effect of Al3Sc precipitates on the yield stress and work hardening of an Al–Mg–Sc alloy
journal, May 2008

The effect of shear-resistant, plate-shaped precipitates on the work hardening of Al alloys: Towards a prediction of the strength–elongation correlation
journal, December 2009

3D printing of Aluminium alloys: Additive Manufacturing of Aluminium alloys using selective laser melting
journal, December 2019

A solution to the hot cracking problem for aluminium alloys manufactured by laser beam melting
journal, September 2020

A Threshold Selection Method from Gray-Level Histograms
journal, January 1979

Back pressure equal channel angular consolidation of pure Al particles
journal, December 2005

New Aluminum Alloys Specifically Designed for Laser Powder Bed Fusion: A Review
journal, March 2019

A review on selective laser sintering/melting (SLS/SLM) of aluminium alloy powders: Processing, microstructure, and properties
journal, October 2015

Physics and phenomenology of strain hardening: the FCC case
journal, January 2003

Predicting slip behavior in alloys containing shearable and strong particles
journal, September 1993

Changing the alloy composition of Al7075 for better processability by selective laser melting
journal, December 2016