Improving the fatigue life of laser powder bed fusion Scalmalloy® by friction stir processing

• Large defects and porosities are removed from L-PBF material by FSP. • Heterogeneous agglomeration of Al 3 (Sc,Zr) nano-precipitates occurs after FSP. • Strengthening heat-treatments lose efficiency on L-PBF + FSP Scalmalloy®. • FSP enhances significantly the technical fatigue strength of L-PBF Scalmalloy®. • FSP improves greatly the total fatigue life of L-PBF Scalmalloy® specimens. A major concern about parts produced by laser powder bed fusion (L-PBF) are intrinsic defects or porosities that are difficult to overcome by simply optimizing the process parameters. As these defects and porosities play a crucial role in the mechanical behaviour, especially in fatigue, additive manufactured parts are often subjected to thermo-mechanical post-treatments. To this end, this work proves Friction Stir Processing (FSP) to be an effective post-treatment to drastically reduce the porosity level. FSP leads to an improvement of 60 % of the technical fatigue strength and by two orders of magnitude of the fatigue life of L-PBF Scalmalloy® specimens. The fatigue performances obtained on FSPed and heat-treated specimens are equivalent or even better than the best fatigue life reported in the literature, whatever their L-PBF conditions and post-treatments, while avoiding Hot Isostatic Pressing. However, FSP reduces the beneficial effect of the conventional strengthening heat-treatment applied to L-PBF Scalmalloy®, lowering the high tensile strength for which the alloy is normally reputed. Advanced characterisation by X-ray microtomography and Transmission Electron Microscopy allows us to reach a better understanding of the involved phenomena: drastic reduction of the biggest defects and heterogeneous nucleation of Sc- and Zr-rich precipitates on grain boundaries and dislocations.