Extending the mechanical property regime of laser powder bed fusion Sc- and Zr-modified Al6061 alloy by manipulating process parameters and heat treatment

Highly dense compositionally modified Al6061 alloys with Sc and Zr (Al6061MOD) were fabricated using the laser powder bed fusion. The as-built AL6061MOD alloy exhibits a bimodal grain size distribution consisting of coarse columnar grains and ultrafine grains, which is tunable by either varying the printing parameters or post-heat treatment. A high laser energy density along with a lower cooling rate, leaving more time for nucleating primary Al3Sc particles, triggers a higher area fraction of ultrafine grains. The heat treatment-induced evolution of microstructure and mechanical properties is jointly influenced by the size of grains and (Al,Si)3(Sc,Zr) particles. The conventional T6 heat treatment triggers coarsening of grains (~5.3 μm) and (Al,Si)3(Sc,Zr) particles (~42 nm), lowering the yield strength (~280 MPa) compared with that of as-built counterparts. On the contrary, direct aging enhances the yield strength (~383 MPa) due to the precipitation of nano-sized secondary Al3(Sc,Zr) particles (~5 nm) as well as retaining the grain size (~690 nm) of ultrafine grains. Concurrent with the tunable strength, the plasticity behaviors (Lüders band and Portevin-Le Chatelier effect) are manipulated correspondingly with varying microstructure. The broad tailoring of microstructure and mechanical property regime can shed light on designing Al alloys targeting the desired applications by manipulating the printing parameters and heat treatment.