Contamination tolerant hypo- and hypereutectic Al-Si-alloys for additive manufacturing

用于增材制造的耐污染亚共晶和过共晶铝硅合金

• 批准号: 493860861
• 负责人: Dr.-Ing. Nils Ellendt
• 金额: --
• 依托单位: Abteilung Verfahrenstechnik
• 依托单位国家: 德国
• 项目类别: Priority Programmes
• 资助国家: 德国
• 项目状态: 未结题
• 来源: https://gepris.dfg.de/gepris/projekt/493860861?language=en
• 关键词: Contamination; tolerant; hypo; hypereutectic; Al

Aluminum, as a lightweight metal, is being used in a wide range of applications in the aerospace and automotive industries. However, the production of primary aluminum is very energy intensive. The recycling of aluminum introduces different contaminations such as for example iron. In aluminum alloys, iron is known to form intermetallic phases, which can lead to embrittlement of the bulk material if their size becomes too large. Synthesis with high cooling rates, like additive manufacturing, may offer an interesting recycling route. This may allow additive manufacturing to be a central process in sustainable closed material chains.Thermophysical properties, such as surface tension and viscosity, are of great importance for the process. However, even small amounts of contamination can have a large effect on these properties. In our project, the effect of Fe contamination on two Al-Si alloys with silicon concentrations of 10 wt.% (hypoeutectic) and 20 wt.% (hypereutectic) will be investigated. While AlSi10 is a common alloy for LPBF, the process window for processing becomes smaller with increasing silicon content. A systematic variation of Fe contamination allows to understand its effect on the base of thermophysical properties, meltpool conditions, phase formation and defect structures of manufactured parts.If the relationships between contamination, thermophysical properties, phase formation and process windows are known, contamination can be compensated by adjusted process conditions.

铝作为一种轻质金属，在航空航天和汽车工业中被广泛应用。然而，原铝的生产是非常耗能的。铝的再循环引入了不同的污染物，例如铁。在铝合金中，已知铁形成金属间相，如果它们的尺寸变得太大，这可能导致块体材料的脆化。具有高冷却速率的合成，如增材制造，可能提供一种有趣的回收途径。这可能使增材制造成为可持续封闭材料链中的核心工艺。热物理性质（如表面张力和粘度）对该工艺至关重要。然而，即使是少量的污染也会对这些性能产生很大的影响。在我们的项目中，Fe污染对两种硅含量为10 wt.%的Al-Si合金的影响（亚共晶）和20重量%（过共晶）将进行研究。虽然AlSi 10是LPBF的常用合金，但随着硅含量的增加，加工的工艺窗口变小。Fe污染的系统性变化有助于了解其对制造零件的热物理性能、熔池条件、相形成和缺陷结构的影响。如果已知污染、热物理性能、相形成和工艺窗口之间的关系，则可以通过调整工艺条件来补偿污染。