Laser powder bed fusion of AA7075 alloy: Influence of process parameters on porosity and hot cracking

Laser powder bed fusion (LPBF) is an attractive technology of manufacturing high-strength aluminium alloy parts for the aircraft and automobile industries, limited by poor processability of these alloys. This work was aimed at finding the process window for the LPBF manufacturing of defect-free components of AA7075 alloy. Optimization of the parameters was performed at each stage of the multi-stage research, i.e. for single tracks, thin walls and volumetric specimens. At each stage, the relation between LPBF parameters and defect formation with a focus on hot cracking was investigated and discussed. Due to the optimization of process parameters, the density of volumetric specimens above 99 % was reached and vaporization losses of the alloying elements were significantly reduced, but solidification cracks could not be eliminated. It was found that solidification cracks were formed by the liquid film rupture mode, mainly along columnar grain boundaries. The EDS microanalysis showed intergranular microsegregation, not only of the main alloying elements (Zn, Mg, Cu) but also of minor elements such as Si. Silicon may play a significant role in increasing susceptibility to cracking by increasing the stability of the liquid film. Reduction in the silicon impurity content in the AA7075 powder gives a chance to reduce susceptibility to cracking with no change of the alloy specification.