Additive manufacturing of metals has been limited to a select group of weldable alloy systems. This limitation is most obvious in the available aluminum alloys where standard high strength aluminum alloys, 2000 and 7000 series, suffer from hot tearing during solidification making them unsuitable for processing in additive manufacturing. HRL has developed a new technique to identify solidification mechanisms reducing this tendency in the unique solidification conditions of direct laser melting. By modifying material feedstock and controlling processing parameters, the hot tear susceptibility can be reduced. In addition, the microstructure and mechanical properties of additively manufacture aluminum alloys can be optimized. We will show trough printing demonstrations and mechanical testing that the application of this process can enable wrought strength from additively manufactured aluminum components.
- Understand the importance of materials science and the limitations conventional alloys in additive manufacturing
- Identify common failure mechanisms in high strength alloys