Laser powder bed fusion of high-strength Sc/Zr-modified Al–Mg alloy:phase selection,microstructural/mechanical heterogeneity,and tensile deformation behavior

Laser powder bed fusion(L-PBF)of Sc/Zr-modified Al-based alloys has recently become a promising method for developing a new generation of high-performance Al alloys.To clarify the modification roles of Sc/Zr elements,an Al–4.66Mg–0.48Mn–0.72Sc–0.33Zr(wt.%)alloy was processed using L-PBF.The effect of the local solidification condition of the molten pool on the precipitation behavior of primary Al_(3)(Sc,Zr)was analyzed based on time-dependent nucleation theory.It was found that primary Al_(3)(Sc,Zr)inevitably precipitated at the fusion boundary,while its precipitation could be effectively suppressed in the inner region of the molten pool.This subsequently induced the formation of a heterogeneousα-Al matrix.After direct aging,the heredity of solidification microstructure introduced heterogeneous secondary Al_(3)(Sc,Zr)precipitates withinα-Al matrix.Owing to the inverse relationship between grain boundary strengthening and precipitation strengthening,the direct-aged sample with dual heterogeneous structures exhibited reduced mechanical heterogeneity,resulting in lowered hetero-deformation-induced hardening.The low strain-hardening capability in the direct-aged sample promoted necking instability while inducing a large Lüders elongation,which effectively improved the tensile ductility.