An integrated computational materials engineering-anchored closed-loop method for design of aluminum alloys for additive manufacturing

A closed-loop approach based on integrated computational material engineering was used to design, fabricate and characterize an Al–1.5Cu–0.8Sc–0.4Zr (wt%) alloy for laser powder bed fusion additive manufacturing (AM). Finalization of composition and prediction of solidification behavior and mechanical properties were done using calculation of phase diagrams (CALPHAD) and analytical tools. The microstructure of the printed alloy in as-built condition consisted of crack-free regions with fine-equiaxed grains which was consistent with CALPHAD results. Yield strength (YS) of ~349 ± 8 MPa was also in more than 90% agreement with predicted YS. The findings demonstrate an efficient methodology for application-based alloy design for AM.