Microstructural Evolution and Mechanical Properties of an Additively Manufactured AlSi10Mg Alloy Post-Processed by Twist Equal Channel Angular Pressing

This study investigates the microstructural evolution and mechanical response of an additively manufactured (PBF-LB/M) AlSi10Mg alloy subjected to severe plastic deformation via two passes of twist channel angular pressing (TCAP). Processing was conducted using Route Bc, with the first pass at 150 °C and the second at 250 °C. For the first time, the evolution from the initial hierarchical AM structure to a refined state was characterized in high-fidelity detail using a novel EBSD detector. The two-pass process transformed the initial structure into a heterogeneous, bimodal microstructure existing in a non-equilibrium state, characterized by a high fraction of low-angle grain boundaries (63%) and significant internal lattice distortion. The mechanical properties were dictated by the processing temperature: a single pass at 150 °C induced work hardening, increasing the yield strength from 450 MPa to 482 MPa. Conversely, the second pass at an elevated temperature of 250 °C promoted significant dynamic recovery. This led to a decrease in yield strength to 422 MPa but concurrently resulted in a substantial increase in ultimate compressive strength to 731 MPa.