Microstructure, precipitates and hardness of selectively laser melted AlSi10Mg alloy before and after heat treatment

The microstructure and precipitates within selectively laser melted (SLM) AlSi10Mg alloys in the as-built state and after T6 heat treatment were examined and correlated to the hardness evolution. The as-built alloy exhibited columnar patterns perpendicular to the build-direction and fish-scale pattern along the build-direction originating from the melt pool. The microstructure consisted of fine Al cells and eutectic structure with up to 4 μm in size. Tiny needle-like Si particles with highly faulted structure were identified within the Al cells and formed semi-coherent interface with the matrix. Nanoscale Si particles and π-Al8Si6Mg3Fe phase were observed to segregate along the cell and grain boundary. Solution heat treatment (SHT) at 520 °C resulted in the dissolution of Al cellular microstructure. Precipitation and coarsening of the Si particles occurred, while the aspect ratio of Si particles remained nearly constant. The π-Al8Si6Mg3Fe phase decomposed into plate-shaped β-Al5SiFe. The artificial aging (AA) at 160 °C did not alter the microstructure but led to the formation of metastable Mg2Si precipitates. The GP zones and β″ were identified through transmission electron microscopy after AA of 6 h, and β″ existed up to AA of 24 h. The hardness decreased after SHT due to the coarsening of the microstructure and reduced solid solution hardening. Hardness reached maximum magnitude after AA of 6–10 h due to the precipitation hardening, and remained relatively unchanged up to AA of 24 h. Microstructure and/or hardness of gas atomized powders and bulk cast AlSi10Mg alloys were also examined as references.