Microstructural evolution and hardening phenomenon caused by aging of AlSi10Mg alloy by laser powder bed fusion

Microstructures and age-hardening phenomena of directly aged (artificial aged) AlSi10Mg alloys fabricated by laser powder bed fusion (LPBF) were characterized using scanning transmission electron microscopy, atom probe tomography, and Vickers hardness testing. The microstructure derived from overlapping melt pools has a full cellular structure consisting of eutectic Si walls surrounding α-Al cells. In the initial stage of aging, solute clusters with density on the order of 10²⁴/m³ were formed in α-Al cells. By prolonging the aging time further, fine Si particles of about 50 nm in diameter precipitated. Before Si precipitation, the hardness of the aged sample was clearly greater than that of the as-built state. With further aging time, the hardness increased further because of the Si precipitation. Cluster analysis revealed that the number density and the size of clusters increased from as-built state by aging, whereas the types of the solute clusters remained almost unchanged by aging. The results indicate that the nanoscale clusters within the α-Al cells, which increase via aging, produce age-hardening effect.