Characteristics of Laser-Remelted Al–Ca–Cu–Mn (Zr) Alloys as a New Material for Additive Manufacturing
In this study, prospects of designing new Al–Ca–Cu–Mn (Zr) alloys for additive manufacturing (AM) were evaluated for the example of laser remelting of thin-sheet rolled products. The new as-cast alloys have a hypereutectic structure containing Al<sub>27</sub>Ca<sub>3</sub>Cu&...
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MDPI AG
2025-07-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/9/7/242 |
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| author | Nikolay V. Letyagin Torgom K. Akopyan Pavel A. Palkin Stanislav O. Cherkasov Anastasiya S. Fortuna Alexandr B. Lyukhter Ruslan Yu. Barkov |
| author_facet | Nikolay V. Letyagin Torgom K. Akopyan Pavel A. Palkin Stanislav O. Cherkasov Anastasiya S. Fortuna Alexandr B. Lyukhter Ruslan Yu. Barkov |
| author_sort | Nikolay V. Letyagin |
| collection | DOAJ |
| description | In this study, prospects of designing new Al–Ca–Cu–Mn (Zr) alloys for additive manufacturing (AM) were evaluated for the example of laser remelting of thin-sheet rolled products. The new as-cast alloys have a hypereutectic structure containing Al<sub>27</sub>Ca<sub>3</sub>Cu<sub>7</sub> primary crystals and ultrafine eutectic particles of (Al,Cu)<sub>4</sub>Ca and Al<sub>27</sub>Ca<sub>3</sub>Cu<sub>7</sub> phases in equilibrium with the aluminum solid solution. The solid solutions are additionally strengthened by alloying with Mn and micro additions of Zr, which contribute to the formation of coarsening-resistant phases without compromising the manufacturability of the alloys. Laser remelting, which simulates AM-typical solidification conditions, promotes the formation of a pseudoeutectic cellular structure without the occurrence of undesirable primary Al<sub>27</sub>Ca<sub>3</sub>Cu<sub>7</sub>. The size of the dendritic cells and eutectic particles is 10 times smaller (for solidification rates of ~200 K/s) than that of the as-cast state. This structure provides for a higher hardness of the laser-remelted alloy (96 HV) as compared to the as-cast alloy (85 HV). Data for the alloy after 350–400 °C long-term annealing for up to 100 h show that the hardness of the Al–Ca–Cu–Mn–Zr alloys declines relatively slowly by ~7.5% as compared to the Zr-free alloy, whose hardness decreases by ~22%. Thus, one can consider these alloys as a promising candidate for AM processes that require high thermal stability. |
| format | Article |
| id | doaj-art-b81a9dbe8455469db51a3320eb8c8a30 |
| institution | Matheson Library |
| issn | 2504-4494 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-b81a9dbe8455469db51a3320eb8c8a302025-07-25T13:26:44ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942025-07-019724210.3390/jmmp9070242Characteristics of Laser-Remelted Al–Ca–Cu–Mn (Zr) Alloys as a New Material for Additive ManufacturingNikolay V. Letyagin0Torgom K. Akopyan1Pavel A. Palkin2Stanislav O. Cherkasov3Anastasiya S. Fortuna4Alexandr B. Lyukhter5Ruslan Yu. Barkov6Sector of Scientific Activity, Moscow Polytechnic University, 38, Bolshaya Semyonovskaya Str., 107023 Moscow, RussiaSector of Scientific Activity, Moscow Polytechnic University, 38, Bolshaya Semyonovskaya Str., 107023 Moscow, RussiaDepartment of Metal Forming, National University of Science and Technology MISIS, 4 Leninsky Pr., 119049 Moscow, RussiaDepartment of Metal Forming, National University of Science and Technology MISIS, 4 Leninsky Pr., 119049 Moscow, RussiaDepartment of Physical Materials Science, National University of Science and Technology MISIS, Leninsky Prospekt 4, 119049 Moscow, RussiaResearch and Educational Center for Laser Technology Implementation, Vladimir State University Named After Alexander and Nikolay Stoletovs, 87 Gorky Str., 600000 Vladimir, RussiaDepartment of Physical Metallurgy of Non-Ferrous Metals, National University of Science and Technology MISIS, Leninsky Prospekt 4, 119049 Moscow, RussiaIn this study, prospects of designing new Al–Ca–Cu–Mn (Zr) alloys for additive manufacturing (AM) were evaluated for the example of laser remelting of thin-sheet rolled products. The new as-cast alloys have a hypereutectic structure containing Al<sub>27</sub>Ca<sub>3</sub>Cu<sub>7</sub> primary crystals and ultrafine eutectic particles of (Al,Cu)<sub>4</sub>Ca and Al<sub>27</sub>Ca<sub>3</sub>Cu<sub>7</sub> phases in equilibrium with the aluminum solid solution. The solid solutions are additionally strengthened by alloying with Mn and micro additions of Zr, which contribute to the formation of coarsening-resistant phases without compromising the manufacturability of the alloys. Laser remelting, which simulates AM-typical solidification conditions, promotes the formation of a pseudoeutectic cellular structure without the occurrence of undesirable primary Al<sub>27</sub>Ca<sub>3</sub>Cu<sub>7</sub>. The size of the dendritic cells and eutectic particles is 10 times smaller (for solidification rates of ~200 K/s) than that of the as-cast state. This structure provides for a higher hardness of the laser-remelted alloy (96 HV) as compared to the as-cast alloy (85 HV). Data for the alloy after 350–400 °C long-term annealing for up to 100 h show that the hardness of the Al–Ca–Cu–Mn–Zr alloys declines relatively slowly by ~7.5% as compared to the Zr-free alloy, whose hardness decreases by ~22%. Thus, one can consider these alloys as a promising candidate for AM processes that require high thermal stability.https://www.mdpi.com/2504-4494/9/7/242Al–Ca–Cu-Mn (–Zr) alloyseutecticlaser remeltingmicrostructurehardnessadditive manufacturing |
| spellingShingle | Nikolay V. Letyagin Torgom K. Akopyan Pavel A. Palkin Stanislav O. Cherkasov Anastasiya S. Fortuna Alexandr B. Lyukhter Ruslan Yu. Barkov Characteristics of Laser-Remelted Al–Ca–Cu–Mn (Zr) Alloys as a New Material for Additive Manufacturing Journal of Manufacturing and Materials Processing Al–Ca–Cu-Mn (–Zr) alloys eutectic laser remelting microstructure hardness additive manufacturing |
| title | Characteristics of Laser-Remelted Al–Ca–Cu–Mn (Zr) Alloys as a New Material for Additive Manufacturing |
| title_full | Characteristics of Laser-Remelted Al–Ca–Cu–Mn (Zr) Alloys as a New Material for Additive Manufacturing |
| title_fullStr | Characteristics of Laser-Remelted Al–Ca–Cu–Mn (Zr) Alloys as a New Material for Additive Manufacturing |
| title_full_unstemmed | Characteristics of Laser-Remelted Al–Ca–Cu–Mn (Zr) Alloys as a New Material for Additive Manufacturing |
| title_short | Characteristics of Laser-Remelted Al–Ca–Cu–Mn (Zr) Alloys as a New Material for Additive Manufacturing |
| title_sort | characteristics of laser remelted al ca cu mn zr alloys as a new material for additive manufacturing |
| topic | Al–Ca–Cu-Mn (–Zr) alloys eutectic laser remelting microstructure hardness additive manufacturing |
| url | https://www.mdpi.com/2504-4494/9/7/242 |
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