The expansion of the laser powder bed melting (LPBF) process material library is essential for further development in the aerospace and automotive industries. Researchers have designed a high-strength, low-cost Al-Mn-Ti-Zr alloy, tailored specifically to the unique conditions of the LPBF process. Prepare aerosolized pre-alloyed powder and use it as a raw material to manufacture LPBF specimens for microstructure inspection and mechanical testing. By using the high solidification rate, an unconventional large amount of Mn (3.7 ± 0.5 wt%) freezes metastable in the α-Al matrix, which significantly promotes solid solution hardening (~104 MPa ≙ 37% yield strength share). The yield strength of the finally obtained sample is 284 ± 3 MPa, the ultimate tensile strength is 320 ± 1 MPa, and the elongation at break is 16.9 ± 0.2%. This new alloy has a bimodal microstructure consisting of alternating fine equiaxed and thick columnar grain regions.
Further microstructure analysis showed that there are a large amount of primary L12 cubic Al3 (Tix Zr1
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