Isotropic and high-strength magnesium alloy parts fabricated by laser foil printing process

Purpose This study aims to present the fabrication of high-strength, isotropic and ductile AZ31B magnesium alloys using the laser foil printing (LFP) process. Using foil as a feedstock, LFP mitigates the oxidation and explosion risks associated with conventional laser additive manufacturing (LAM) processes. This study characterized the microstructure, hardness and tensile properties of the LFP-fabricated AZ31B parts and highlighted their superior mechanical performance. Design/methodology/approach AZ31B magnesium alloy parts were fabricated using LFP, and their microstructure, hardness and tensile properties were analyzed. Vickers microhardness and tensile tests were conducted to evaluate mechanical performance. Electron backscatter diffraction (EBSD) was used to examine the grain structure and orientation, whereas X-ray diffraction (XRD) was used to validate the crystallographic texture. Findings The LFP process successfully fabricated AZ31B Mg alloy parts with a high relative density of approximately 99.9%. The parts exhibited superior and isotropic tensile strengths and elongation compared to other LAM processes. The EBSD analysis revealed a finer grain structure owing to the higher cooling rate, whereas the pole figure analysis confirmed a preferred {0001} grain orientation, consistent with the XRD patterns. Originality/value This study demonstrates the successful fabrication of high-strength, isotropic and ductile AZ31B magnesium alloys using the LFP process, which mitigates the oxidation and explosion risks associated with magnesium alloys. This provided a comprehensive analysis of the microstructure and mechanical properties, highlighting the advantages of LFP over conventional LAM processes. These findings provide valuable insights into the grain refinement and texture control in Mg alloys.