Al–Mn–Cr–Zr-based alloys tailored for powder bed fusion-laser beam process: Alloy design, printability, resulting microstructure and alloy properties

Abstract This study introduces a family of unique Al–Mn–Cr–Zr-based aluminium alloys illustrated by two ternary and one quaternary variants. The choice of alloy compositions has created a system resistant to solidification cracking while retaining high amount of solutes in solid solution in as-printed condition. Good relative density (~ 99.5%) has been demonstrated along with microstructural study supported by X-ray diffraction to display solidification structure with nanometric precipitate formation in small amounts in as-printed condition. High levels of Mn and Cr produce significant solid solution strengthening reaching hardness of up to 102 HV in as-printed condition. Additionally, the combination of Mn, Cr and Zr is shown to be important to control precipitation strengthening upon direct ageing and coarsening resistance due to slow diffusivity. To elucidate the concept of precipitation strengthening, one set of alloys was aged at 678 K between 0 and 10 h and microhardness results showed that average hardness response reached 130 HV for the quarternary alloy. Graphical abstract