Microstructure and Fatigue Behavior of High-Performance Aluminum Alloy Al2024 Produced by Laser Powder Bed Fusion

Aluminum-based alloys are widely used in high-performance structural applications. Therefore, the opportunity to fabricate aluminum components using Laser Powder Bed Fusion (L-PBF) is a matter of great interest. In particular, the Al2024 alloy is extensively used for conventional part production but its processability by L-PBF remains a challenge because of its hot cracking sensitivity upon solidification. The new Reactive Additive Manufacturing (RAM) technology by Elementum 3D enables the production of innovative powders characterized by metal matrix and nanoceramic particles that can be processed using L-PBF. The ceramic nanoparticles of 2 % by weight improves properties and prevents Al2024-RAM2 alloy cracking during solidification. The present study investigates the fatigue performance of Al2024-RAM2 alloy manufactured by L-PBF using an SLM 280 HL equipment with a nominal layer thickness of 60 µm. A set of miniature vertical fatigue specimens were manufactured then underwent to a heat treatment T6. The specimens were tested in the as-built state (i.e., without any surface post-processing) under cyclic plane bending at a load ratio R = 0 at a frequency of 25 Hz. The fatigue performance was determined and compared to that of another Al-alloy produced by L-PBF. Specimens were examined by using optical microscopy and SEM analysis to determine the microstructure. The fracture surfaces of vertical specimens were investigated in the SEM to determine the mechanisms of crack initiation.