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Strong 3D-printed aluminium reinforced with ductile-transformable eutectic nano-skeleton.

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Additive manufacturing of lightweight metals now offers improved strength and ductility. A novel ductile-transformable eutectic nano-skeleton (DT-ENS) design overcomes the strength-ductility trade-off in aluminum alloys.

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Area of Science:

  • Materials Science
  • Metallurgy
  • Additive Manufacturing

Background:

  • Lightweight metals for additive manufacturing (AM) exhibit limited strength-ductility synergy, hindering high-performance structural applications.
  • Existing AM aluminum alloys struggle to balance high strength with sufficient ductility.

Purpose of the Study:

  • To develop a new design strategy for additively manufactured alloys with enhanced strength-ductility synergy.
  • To investigate the potential of ductile-transformable eutectic nano-skeletons (DT-ENS) for overcoming the strength-ductility trade-off.

Main Methods:

  • Utilized non-equilibrium solidification to create DT-ENS in a near-eutectic Al-Er system.
  • Developed an alloy family featuring a deformable Al3(Er,Mg) nano-skeleton.
  • Employed laser powder bed fusion (LPBF) for alloy fabrication.

Main Results:

  • Achieved AM Al-Er alloys with strengths ranging from 600-700 MPa.
  • Demonstrated good printability and useful ductility in the developed alloys.
  • Observed deformation twinning and strain-induced formation of 9R-type long-period stacking ordered structures within the Al3(Er,Mg) skeleton.

Conclusions:

  • The DT-ENS strategy establishes a new benchmark for structural AM aluminum alloys.
  • This approach provides a viable route for developing ductile intermetallics to resolve the strength-ductility compromise.
  • Additive manufacturing facilitates the discovery of novel alloy systems and deformation mechanisms.