The Role of Temperature Field Distribution in the Microstructural Evolution of High-Strength Aluminum Alloys During Laser Powder Bed Fusion

Laser powder bed fusion (LPBF) of high-strength aluminum alloy 7075 (AA7075) is severely limited by hot cracking. However, the underlying mechanisms, particularly the coupling between thermal fields, solidification microstructure, and cracking behavior, remain insufficiently clarified. This study elucidates these mechanisms by integrating experimental characterization with thermal simulation to investigate the temperature field, microstructure, and cracking relationships in both AA7075 and a crack-resistant 7075-Er-Zr alloy. Results show that coarse hot crack morphology is highly dependent on linear energy density EL. In AA7075, EL < 450 J/m promotes laterally inclined cracks (short, narrow cracks extending from the melt pool boundary toward the track center), whereas EL higher than that value leads to the continuous centerline cracks (long, wide cracks along the track center). Fine microcracks are also observed at melt pool boundaries. The 7075-Er-Zr alloy demonstrates superior crack resistance. At EL = 600 J/m, longitudinal centerline cracks still penetrate along the track, but the alloy achieves crack-free tracks at 200 W with scanning speeds above 1000 mm/s, otherwise exhibiting only short discontinuous cracks. Microcracks at melt pool boundaries are markedly suppressed in the modified alloy. The enhanced crack resistance is attributed to Er/Zr-induced grain refinement and a transition to an equiaxed grain structure, which disrupts intergranular gaps. Critically, thermal simulations identify an annular region with a peak temperature gradient. In AA7075, this region develops aligned columnar grains that facilitate both microcracks and centerline cracks. In the 7075-Er-Zr alloy, microcracks are fully eliminated within this region. However, a residual crystallographic texture persists in the annular region, which promotes the continued occurrence of centerline cracks under high energy density (e.g., EL = 600 J/m). The annular region remains a critical weak link, and its microstructural control determines the prevailing crack type. This work provides a fundamental understanding of the thermal-microstructural origins of cracking and offers a theoretical foundation for developing crack-resistant aluminum alloys via LPBF.