Aluminum–Calcium Alloy for Laser Powder Bed Fusion

Developing specialized aluminum alloys for additive processes is a strategic approach to achieve both strength and mass reduction in high-performance products. The prospects of the new metallic powder composition of Al3Ca2La2Mn0.4Zr alloy for laser powder bed fusion (LPBF) have been studied. It has been found that the best printing mode, providing a more than 99.0% density of the specimens, includes substrate heating to 150 °C and printing with a 350 W laser power, a 1500 mm/s printing speed, a 0.08 mm hatch distance and a 0.03 mm layer thickness (energy density 97.2 J/mm2). The optimal printing mode provides for the following strength parameters: UTS 366 ± 5 MPa, yield strength 223 ± 8 MPa, and relative elongation 30 ± 3%. The alloy exhibits high thermal stability for the structure and its properties. Annealing temperatures below 300 °C have no critical effect on the alloy hardness: the hardness decreases by less than 10% of the initial 110 ± 3 HV. At 350 °C, the hardness decreases by 25.5% (82 ± 2 HV); 100 h exposure at 350 °C reduces the UTS to 265 ± 2 MPa and the yield strength to 178 ± 10 MPa, while maintaining the relative elongation of 29 ± 2%.