Synergistic strengthening of crack-free Al–Zn–Mg–Cu alloys with hierarchical microstructures achieved via laser powder bed fusion

Crack-free Al–Zn–Mg–Cu alloy, processed by laser powder bed fusion, displays a characteristic microstructure comprising fine equiaxed grains (EGs) and coarse columnar grains (CGs). Notably, the CGs show a high hardness compared to EGs due to the high density of in-situ precipitates. Analysis of mechanical properties takes into account the precipitates in the grain and hierarchical differences in grain morphologies near the melt pool boundary. Strengthening mechanisms are elucidated through synergistic hetero-deformation-induced strengthening, where multi-modal-sized EGs induce significant strain gradients within EG regions. Our findings demonstrate the potential to enhance strength of Al–Zn–Mg–Cu-based alloy in as-built state through architecting microstructures.