Laser Powder-Bed Fusion of Aluminum-Scandium (Al-Sc) Alloys

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The objective of the proposed research project is to identify the process-structure-property relationships for laser powder-bed fusion of various Aluminum-Scandium (Al-Sc) alloys. Scandium (Sc), a rare earth element, is one of the most effective microalloying elements to strengthen Al alloys. It imparts increased strength and desirable properties to aluminum. Scandium additions generate strength by promoting a smaller, homogenous grain structure in alloys during solidification. Very small quantities of Scandium (between 0.05% and 0.5% Sc) are usually added to aluminum for better strength response. The main goal of this project is to design and manufacture a new Al-Sc alloy with an enhanced strength-to-weight ratio for use by the Canadian automotive and aerospace industries. The mechanical properties of Al-Sc parts produced using laser additive manufacturing need to be known for the automotive and aerospace industries. This project is a collaborative effort between McMaster's Additive Manufacturing Group and Imperial Mining Group Ltd. (Imperial). The long-term impact of this project is the development of additional capacity to manufacture automotive and aerospace components in Canada using additive manufacturing of Al-Sc alloy.