MATERIALS SCIENCE AND ENGINEERING

Composition design of high-strength and heat-resistant Al−Si−Fe alloy for powder bed fusion using laser beam

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  • 1. School of Materials Science and Engineering, North University of China, Taiyuan 030051, China;
    2. Institute of Special Metal Materials and Equipment, North University of China, Taiyuan 030051, China;
    3. School of Energy Power and Mechanical Engineering, North China Electric Power University, Beijing 102206, China;
    4. Advanced Manufacturing and Intelligent Equipment Industrial Research Institute, Hai’an & Taiyuan University of Technology, Hai’an 226600, China;
    5. State Key Laboratory of Powder Metallurgy, Central South University, Changsha 410083, China

Online published: 2025-12-16

Abstract

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.

Cite this article

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

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