Achieving superior strength-plasticity performance in laser powder bed fusion of AlSi10Mg via high-speed scanning remelting

The limited mechanical properties of Al–Si alloys hinder their application in demanding and extreme conditions. The cracking tendency of high-strength aluminum alloys and high-cost of rare-earth elements pose challenges for the large-scale application of aluminum alloys in additive manufacturing. The novel and practical high-speed scanning remelting proposed in this study enables Al–Si alloys to exhibit significant proportion of fine microstructures and nano-precipitates, surpassing the mechanical properties of aluminum alloys fabricated by normal methods with exceptional strength (496.1 ± 5.8 MPa) and plasticity (21.4 ± 0.9%). This in-situ microstructure control method opens new pathways for the application in demanding engineering contexts.