Additive manufacturing of an ultrastrong, deformable Al alloy with nanoscale intermetallics

Anyu Shang, Benjamin Stegman, Kenyi Choy, Tongjun Niu, Chao Shen, Zhongxia Shang, Xuanyu Sheng, Jack Lopez, Luke Hoppenrath, Bohua Peter Zhang, Haiyan Wang, Pascal Bellon and Xinghang Zhang ()
Additional contact information
Anyu Shang: Purdue University
Benjamin Stegman: Purdue University
Kenyi Choy: University of Illinois Urbana-Champaign
Tongjun Niu: Purdue University
Chao Shen: Purdue University
Zhongxia Shang: Purdue University
Xuanyu Sheng: Purdue University
Jack Lopez: Purdue University
Luke Hoppenrath: Purdue University
Bohua Peter Zhang: Purdue University
Haiyan Wang: Purdue University
Pascal Bellon: University of Illinois Urbana-Champaign
Xinghang Zhang: Purdue University

Nature Communications, 2024, vol. 15, issue 1, 1-12

Abstract: Abstract Light-weight, high-strength, aluminum (Al) alloys have widespread industrial applications. However, most commercially available high-strength Al alloys, like AA 7075, are not suitable for additive manufacturing due to their high susceptibility to solidification cracking. In this work, a custom Al alloy Al92Ti2Fe2Co2Ni2 is fabricated by selective laser melting. Heterogeneous nanoscale medium-entropy intermetallic lamella form in the as-printed Al alloy. Macroscale compression tests reveal a combination of high strength, over 700 MPa, and prominent plastic deformability. Micropillar compression tests display significant back stress in all regions, and certain regions have flow stresses exceeding 900 MPa. Post-deformation analyses reveal that, in addition to abundant dislocation activities in Al matrix, complex dislocation structures and stacking faults form in monoclinic Al9Co2 type brittle intermetallics. This study shows that proper introduction of heterogeneous microstructures and nanoscale medium entropy intermetallics offer an alternative solution to the design of ultrastrong, deformable Al alloys via additive manufacturing.

Date: 2024
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DOI: 10.1038/s41467-024-48693-4

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