Nano characterization of a next-generation aluminium alloy for 3D-printing

The lack of metallic materials tailored to the metallurgical conditions of laser-based additive manufacturing is still a critical bottleneck for this disruptive manufacturing technology. We are currently investigating a new Al-Fe-Zr alloy that has been specifically designed to exploit the rapid solidification nature of laser powder bed fusion (LPBF). While preliminary laboratory investigations show that the alloy can yield mechanical performance beyond that of conventional Al alloys processed by LPBF, the fundamental mechanisms of nano-structural feature formation needs investigation at the nanometric level to fully understand and optimize processing and post-processing conditions. We propose a complementary experiment combining in operando X-ray radiography during LPBF (already carried out at ID19) with nanotomography at ID16A. The results will help reveal the underlying mechanisms governing microstructural formation and evolution during LPBF processing and subsequent heat treatment.