A combination of casting
and laser remelting was employed to develop a high-strength and heat-resistant
Al−Si−Fe alloy suitable for powder bed fusion using a laser beam (PBF-LB). By
clarifying the effects of the incorporated elements and their contents on the
microstructure and mechanical performance of Al−Si−Fe alloys, the composition
was optimized as Al−11Si−2.5Fe−2Mn−1.2Ni−0.4Cr (in wt.%). The optimized
alloy was subsequently validated using PBF-LB, which exhibited favorable
machinability, achieving a density of 99.8%. The room-temperature tensile
strength of the PBF-LB manufactured Al−Si−Fe alloy reached
(512.76±3.26) MPa, with a yield strength of (337.79±2.36) MPa and an
elongation of (2.98±0.07)%. The enhanced room-temperature mechanical properties
could be mainly attributed to the combined effects of fine-grain strengthening,
solid solution strengthening, and precipitation strengthening. At 300 °C,
the high-temperature tensile strength of the developed alloy reached
(222.47±6.41) MPa, with a yield strength of (164.25±11.40) MPa and an
elongation of (8.88±0.33)%, outperforming those of existing alloys documented
in the literature. The improved high-temperature mechanical performance was
primarily provided by the three-dimensional network comprising cellular
heat-resistant Al17(FeMnNiCr)4Si2 and α-Al(FeMn)Si phases.
Wen-zhe GAO, Li ZHANG, Kai-yang LI, Xiao-hui YANG, Jin-fang ZHANG, Jian-hong WANG, Hong XU, Pei-kang BAI, Yuan-kui CAO, Bin LIU, Xiao-feng LI
. Composition design of high-strength and heat-resistant Al−Si−Fe alloy for
powder bed fusion using laser beam[J]. Transactions of Nonferrous Metals Society of China, 2025
, 35(11)
: 3561
-3577
.
DOI: 10.1016/S1003-6326(25)66899-3