材料科学与技术 ›› 2019, Vol. 35 ›› Issue (2): 270-284.DOI: 10.1016/j.jmst.2018.09.004
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收稿日期:2018-03-29修回日期:2018-04-26接受日期:2018-05-22出版日期:2019-02-05发布日期:2018-12-21
A review of selective laser melting of aluminum alloys: Processing, microstructure, property and developing trends
Jinliang Zhanga, Bo Songa*(
), Qingsong Weia, Dave Bourellb, a
- aState Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China
bDave Bourell Laboratory for Freeform Fabrication, Mechanical Engineering Department, The University of Texas at Austin, Austin, TX, 78712, USA
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Received:2018-03-29Revised:2018-04-26Accepted:2018-05-22Online:2019-02-05Published:2018-12-21 -
Contact:Song Bo -
About author:These authors contributed equally to this work.
引用本文
. [J]. 材料科学与技术, 2019, 35(2): 270-284.
Jinliang Zhang, Bo Song, Qingsong Wei, Dave Bourell, . A review of selective laser melting of aluminum alloys: Processing, microstructure, property and developing trends[J]. J. Mater. Sci. Technol., 2019, 35(2): 270-284.
Fig. 1. Classification of cast aluminum alloys and wrought aluminum alloys: (a) cast aluminium alloys. (b) wrought aluminium alloys. Non-heat treatable aluminium alloys are in blue and heat treatable aluminum alloys are in red.
Fig. 1. Classification of cast aluminum alloys and wrought aluminum alloys: (a) cast aluminium alloys. (b) wrought aluminium alloys. Non-heat treatable aluminium alloys are in blue and heat treatable aluminum alloys are in red.
Table 1 Properties of aluminium series alloys.
| Series | Types | elements | Performance |
|---|---|---|---|
| 1××× | non-heat treatable | Pure Al (≥99.00%) | Low strength, good corrosion resistance and conductivity, easy processing |
| 2××× | heat treatable | Al-Cu/Al-Cu-Mg | Hard-aluminium alloy. High strength, good heat resistance, poor corrosion resistance |
| 3××× | non-heat treatable | Al-Mn | Antirust aluminium alloy. Low strength, cold-working-hardening, good plasticity and weldability |
| 4××× | non-heat treatable | Al-Si | High silicon, low melting point, good weldability, good heat and wear resistance |
| 5××× | non-heat treatable | Al-Mg | High magnesium, good corrosion resistance and weldability |
| 6××× | heat treatable | Al-Mg-Si | Medium strength, good formability, weldability and machinability |
| 7××× | heat treatable | Al-Zn-Mg | Very high strength, cannot be welded, poor corrosion resistance |
| 8××× | / | Other elements | / |
| 9××× | / | Spare alloys | / |
Table 1 Properties of aluminium series alloys.
| Series | Types | elements | Performance |
|---|---|---|---|
| 1××× | non-heat treatable | Pure Al (≥99.00%) | Low strength, good corrosion resistance and conductivity, easy processing |
| 2××× | heat treatable | Al-Cu/Al-Cu-Mg | Hard-aluminium alloy. High strength, good heat resistance, poor corrosion resistance |
| 3××× | non-heat treatable | Al-Mn | Antirust aluminium alloy. Low strength, cold-working-hardening, good plasticity and weldability |
| 4××× | non-heat treatable | Al-Si | High silicon, low melting point, good weldability, good heat and wear resistance |
| 5××× | non-heat treatable | Al-Mg | High magnesium, good corrosion resistance and weldability |
| 6××× | heat treatable | Al-Mg-Si | Medium strength, good formability, weldability and machinability |
| 7××× | heat treatable | Al-Zn-Mg | Very high strength, cannot be welded, poor corrosion resistance |
| 8××× | / | Other elements | / |
| 9××× | / | Spare alloys | / |
Fig. 2. Schematic diagram of selective laser melting [14].
Fig. 2. Schematic diagram of selective laser melting [14].
Fig. 3. Diagram of interaction between laser and powder bed [28].
Fig. 3. Diagram of interaction between laser and powder bed [28].
Fig. 4. Epitaxial solidification and competitive growth of welded molten zone [37].
Fig. 4. Epitaxial solidification and competitive growth of welded molten zone [37].
Fig. 5. Conditions of constitutional supercooling.
Fig. 5. Conditions of constitutional supercooling.
Fig. 6. Grain map measured by electron backscattered diffraction technology [44].
Fig. 6. Grain map measured by electron backscattered diffraction technology [44].
Fig. 7. Schematic diagram of balling phenomenon. (a) Less molten substrate material. (b) More molten substrate material.
Fig. 7. Schematic diagram of balling phenomenon. (a) Less molten substrate material. (b) More molten substrate material.
Fig. 8. Schematic diagram of droplet splash during SLM [14].
Fig. 8. Schematic diagram of droplet splash during SLM [14].
Fig. 9. Diagram of velocity field of evaporated metal. (a) He. (b) Ar. (c) N2 [71].
Fig. 9. Diagram of velocity field of evaporated metal. (a) He. (b) Ar. (c) N2 [71].
Fig. 10. Formation mechanism and morphology of oxide film [102]. (a) Oxide disruption of the molten pool. (b) The walls of oxide films. (c) SEM image of oxide films after deep corrosion.
Fig. 10. Formation mechanism and morphology of oxide film [102]. (a) Oxide disruption of the molten pool. (b) The walls of oxide films. (c) SEM image of oxide films after deep corrosion.
Fig. 11. Al-Si phase diagram.
Fig. 11. Al-Si phase diagram.
Fig. 12. (a) SLMed Al-Si alloy microstructure at low magnification. (b) SLMed Al-Si alloy microstructure at high magnification. (c) Inverse polar figure obtained by EBSD [125]. (d) Casting Al-Si alloy microstructure [124].
Fig. 12. (a) SLMed Al-Si alloy microstructure at low magnification. (b) SLMed Al-Si alloy microstructure at high magnification. (c) Inverse polar figure obtained by EBSD [125]. (d) Casting Al-Si alloy microstructure [124].
Table 2 Mechanical properties of SLMed Al-Si alloys from different literatures.
| Material | Condition | Hardness (HV) | Yield strength (MPa) | Ultimate Tensile Strength (MPa) | Elongation (%) | Reference |
|---|---|---|---|---|---|---|
| AlSi10Mg | As-SLMed | — | ～270 | ～375 | ～4 | [ |
| As-SLMed | ～136 | - | ～396 | ～3.5 | [ | |
| As-SLMed | 139-146 | ～360 | ～6 | [ | ||
| As-SLMed | ～133 | ～322 | ～434 | ～5.3 | [ | |
| SLM + solution at 450 °C | ～90 | ～196 | ～282 | ～13.4 | [ | |
| SLM++solution at 550 °C | ～60 | ～90 | ～168 | ～23.7 | [ | |
| SLM + T6 | ～78 | - | ～187 | ～19.5 | [ | |
| As-SLMed | 125 | ～268 | ～333 | ～1.4 | [ | |
| SLM + T6 | ～103 | ～239 | ～292 | ～3.9 | [ | |
| As-SLMed | ～311 | ～391 | ～7.2 | [ | ||
| As-SLMed | ～300 | ～455 | ～5.4 | [ | ||
| As-SLMed | ～255 | ～377 | ～1.2 | [ | ||
| SLM + annealing | ～158 | ～256 | ～9.9 | [ | ||
| SLM + T6 | ～210 | ～284 | ～4.9 | [ | ||
| AlSi12 | SLM + solution | ～110 | ～190 | ～25 | [ | |
| As-SLMed | ～260 | ～380 | ～3 | [ | ||
| SLM + annealing | ～95 | ～140 | ～15 | [ | ||
| AlSi9Mg | As-SLMed | 328 | 379 | ～8.1 | [ | |
| AlSi7Mg0.3 | As-SLMed | ～200 | ～400 | 12-17 | [ | |
| AlSiMg0.75 | As-SLMed | ～150 | 354.9 | 427.7 | 2.54 | [ |
| SLM + annealing | ～110 | 275.4 | 360.2 | 4.57 | [ |
Table 2 Mechanical properties of SLMed Al-Si alloys from different literatures.
| Material | Condition | Hardness (HV) | Yield strength (MPa) | Ultimate Tensile Strength (MPa) | Elongation (%) | Reference |
|---|---|---|---|---|---|---|
| AlSi10Mg | As-SLMed | — | ～270 | ～375 | ～4 | [ |
| As-SLMed | ～136 | - | ～396 | ～3.5 | [ | |
| As-SLMed | 139-146 | ～360 | ～6 | [ | ||
| As-SLMed | ～133 | ～322 | ～434 | ～5.3 | [ | |
| SLM + solution at 450 °C | ～90 | ～196 | ～282 | ～13.4 | [ | |
| SLM++solution at 550 °C | ～60 | ～90 | ～168 | ～23.7 | [ | |
| SLM + T6 | ～78 | - | ～187 | ～19.5 | [ | |
| As-SLMed | 125 | ～268 | ～333 | ～1.4 | [ | |
| SLM + T6 | ～103 | ～239 | ～292 | ～3.9 | [ | |
| As-SLMed | ～311 | ～391 | ～7.2 | [ | ||
| As-SLMed | ～300 | ～455 | ～5.4 | [ | ||
| As-SLMed | ～255 | ～377 | ～1.2 | [ | ||
| SLM + annealing | ～158 | ～256 | ～9.9 | [ | ||
| SLM + T6 | ～210 | ～284 | ～4.9 | [ | ||
| AlSi12 | SLM + solution | ～110 | ～190 | ～25 | [ | |
| As-SLMed | ～260 | ～380 | ～3 | [ | ||
| SLM + annealing | ～95 | ～140 | ～15 | [ | ||
| AlSi9Mg | As-SLMed | 328 | 379 | ～8.1 | [ | |
| AlSi7Mg0.3 | As-SLMed | ～200 | ～400 | 12-17 | [ | |
| AlSiMg0.75 | As-SLMed | ～150 | 354.9 | 427.7 | 2.54 | [ |
| SLM + annealing | ～110 | 275.4 | 360.2 | 4.57 | [ |
Table 3 Mechanical properties of AlSi12 via SLM and casting in literature [124].
| Test condition | YS (MPa) | UTS (MPa) | ef (%) | Kq (MPam) | ΔKth (MPam) | m | FS (MPa) | FS/UTS |
|---|---|---|---|---|---|---|---|---|
| AS∥ | 270.1±10 | 325±20 | 4.4±0.7 | 46.7 | 1.1 | 3.1 | 60 | 0.22 |
| AS⊥ | 274.8±8 | 296.1±20 | 2.2±0.3 | 37.9 | 1.4 | 3.7 | — | — |
| HS∥ | 153.4±5 | 228±13 | 5.3±0.7 | 21.7 | 2.0 | 3.1 | 110 | 0.41 |
| HS⊥ | 150.3±17 | 210.1±20 | 4.2±0.3 | 19.3 | 3.1 | 3.7 | — | — |
| CS∥ | 262.4±17 | 330.7±15 | 3.9±0.6 | 47.0 | 1.3 | 3.4 | 70 | 0.22 |
| CS⊥ | 276.6±15 | 302.7±15 | 2.3±0.3 | 34.5 | 1.3 | 3.9 | — | — |
| CC | 104.2±11 | 192.3±15 | 9±0.5 | 11.1 | 3.4 | 5.4 | 94.5 | 0.49 |
Table 3 Mechanical properties of AlSi12 via SLM and casting in literature [124].
| Test condition | YS (MPa) | UTS (MPa) | ef (%) | Kq (MPam) | ΔKth (MPam) | m | FS (MPa) | FS/UTS |
|---|---|---|---|---|---|---|---|---|
| AS∥ | 270.1±10 | 325±20 | 4.4±0.7 | 46.7 | 1.1 | 3.1 | 60 | 0.22 |
| AS⊥ | 274.8±8 | 296.1±20 | 2.2±0.3 | 37.9 | 1.4 | 3.7 | — | — |
| HS∥ | 153.4±5 | 228±13 | 5.3±0.7 | 21.7 | 2.0 | 3.1 | 110 | 0.41 |
| HS⊥ | 150.3±17 | 210.1±20 | 4.2±0.3 | 19.3 | 3.1 | 3.7 | — | — |
| CS∥ | 262.4±17 | 330.7±15 | 3.9±0.6 | 47.0 | 1.3 | 3.4 | 70 | 0.22 |
| CS⊥ | 276.6±15 | 302.7±15 | 2.3±0.3 | 34.5 | 1.3 | 3.9 | — | — |
| CC | 104.2±11 | 192.3±15 | 9±0.5 | 11.1 | 3.4 | 5.4 | 94.5 | 0.49 |
Fig. 13. Schematic diagram of scanning strategy [124]: (a) unidirectional scanning strategy. (b) checkerboard scanning strategy.
Fig. 13. Schematic diagram of scanning strategy [124]: (a) unidirectional scanning strategy. (b) checkerboard scanning strategy.
Fig. 14. Possible crack propagation tracks of SLM specimens [147]. (a) ∥ direction. (b) ⊥direction.
Fig. 14. Possible crack propagation tracks of SLM specimens [147]. (a) ∥ direction. (b) ⊥direction.
Fig. 15. Microstructure of Al-Si12 after heat treatment [118]. (a) 15 min, (b) 30 min, (c) 2 h, (d) 4 h.
Fig. 15. Microstructure of Al-Si12 after heat treatment [118]. (a) 15 min, (b) 30 min, (c) 2 h, (d) 4 h.
Fig. 16. SEM images of Al-Cu-Mg samples. (a) and (b) SLMed Al-Cu-Mg samples [163]. (c) Al-Cu-Mg alloy after heat treatment [164]. (d) SLMed Zr/Al-Cu-Mg alloy [166].
Fig. 16. SEM images of Al-Cu-Mg samples. (a) and (b) SLMed Al-Cu-Mg samples [163]. (c) Al-Cu-Mg alloy after heat treatment [164]. (d) SLMed Zr/Al-Cu-Mg alloy [166].
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