Analysis demonstrates improved tensile strength and ductility in selective-laser-melted aluminum alloys, suggesting new avenues for material design.
The Zn/Mg ratio and precipitated phase is a critical in controlling hot cracking and mechanical properties of Al–Zn–Mg–Cu–Sc–Zr alloys fabricated by selective laser melting (SLM). This study systematically examines the effects of Zn/Mg ratios on the microstructure and mechanical performance of crack-free alloys after T6 heat treatment. Thermo-Calc simulations were employed to predict phase stability and interpret non-equilibrium precipitation behavior. A lower Zn/Mg ratio (2.67) promoted Mg segregation, while a higher ratio (3.67) caused Al–Zn eutectic formation. The alloy with a Zn/Mg ratio of 3 exhibited the best balance of strength and ductility, achieving a tensile strength of 678 ± 10 MPa, yield strength of 667 ± 8 MPa, and elongation of 9 ± 1.7 %. Quantitative analysis revealed that grain refinement and precipitation dominated the strengthening contributions. EBSD results showed average grain sizes of 4.16, 1.82, and 4.87 μm for the respective Zn/Mg ratios, indicating pronounced refinement and a non-monotonic size evolution. This work provides experimental and theoretical insights for designing high-performance SLM Al–Zn–Mg–Cu alloys with tunable microstructures and properties.
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Li et al. (2025) studied this question.
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