Enhancing the Printability of Laser Powder Bed Fusion-Processed Aluminum 7xxx Series Alloys Using Grain Refinement and Eutectic Solidification Strategies

As the most commercially developed metal additive process, laser powder bed fusion (LPBF) is vital to advancing several industry sectors, enabling high-precision part production across aerospace, biomedical, and manufacturing industries. Al 7075 alloy offers low density and high-specific strength yet faces LPBF challenges such as hot cracking and porosity due to rapid solidification, thermal gradients, and a wide freezing range. To address these challenges, this study proposes an integrated computational and experimental framework to enhance the LPBF processability of Al 7xxx alloys by compositional modification. Using the Calculation of Phase Diagram approach, printable Al 7xxx compositions were designed by adding grain refiners (V and/or Ti) and a eutectic solidification enhancer (Mg) to Al 7075 alloy to enable grain refinement and eutectic solidification. Subsequent LPBF experiments and characterization tests, such as metallography (scanning electron microscopy), energy-dispersive X-ray spectroscopy, X-ray diffraction, and X-ray micro-computed tomography, confirmed the production of refined microstructures with reduced defects. This study contributes to existing approaches for producing high-quality Al 7xxx alloy parts without significant compositional deviations using an integrated computational and experimental approach. Finally, aligning with the Materials Genome Initiative, this study contributes to the development and industrial adoption of advanced materials.