Harnessing centrifugal casting for designing aluminum alloys adapted to laser powder bed fusion

Research output: Contribution to journal › Research article › Contributed › peer-review

Contributors

  • Philip Grimm - , Freiberg University of Mining and Technology, Leibniz Institute for Solid State and Materials Research Dresden (Author)
  • Lars Giebeler - , Leibniz Institute for Solid State and Materials Research Dresden (Author)
  • Julia Kristin Hufenbach - , Freiberg University of Mining and Technology, Leibniz Institute for Solid State and Materials Research Dresden (Author)
  • RTG 2868 D³ - Data-driven Design of Resilient Metamaterials

Abstract

Additive manufacturing technologies like laser-based powder bed fusion of metals (PBF-LB/M) enable the fabrication of lightweight, intricate aluminum structures. However, harsh processing conditions drastically limit the processability of alloys. Thus, customized materials must be developed for PBF-LB/M, which is a tedious task. Fast screening methods can facilitate the identification of suitable compositions. Here, gravity casting (CG) with enhanced cooling rates and centrifugal casting (CC) as rapid cooling technique were employed to investigate its suitability as material pre-screening technique. Advantageously, only a small amount of starting elements are needed, no powder is required, and high cooling rates can be applied. By this approach, the influence of a wide range of cooling rates (101–105 K/s) on the microstructure and the mechanical properties of AlSi12 processed by GC, CC and PBF-LB/M was investigated. The microstructure transformed from a degenerated eutectic dispersed with coarse dendritic α-Al (GC) via a fibrous Al–Si eutectic combined with fine dendritic α-Al (CC) to a cellular α-Al in a heterogenous microstructure (PBF-LB/M). With increasing cooling rates, the average grain size shrank from 198 μm down to 10 μm. Under compressive loading, the 0.2% yield strength (YS) increased at the expense of ductility primarily due to refined grains and changed morphology of Si. Despite a different grain size and YS between PBF-LB/M and the CC specimens, the compressive stress of CC specimens at 10% strain reached almost 82% of the strength in PBF-LB/M. Furthermore, the ultimate compressive strength and total strain of PBF-LB/M and CC specimens were almost identical.

Details

Original languageEnglish
Pages (from-to)2118-2133
Number of pages16
JournalJournal of Materials Research and Technology
Volume39
Publication statusPublished - 1 Nov 2025
Peer-reviewedYes
Externally publishedYes

Keywords

Keywords

  • AlSi12, Centrifugal casting, Cooling rate, Mechanical properties, Metal additive manufacturing, Microstructure