Multi-scale microstuctural investigation of a new Al-Mn-Ni-Cu-Zr aluminium alloy processed by laser powder bed fusion

Traditional high strength aluminum alloys such as the 2xxx or 7xxx series are prone to cracking when processed by additive manufacturing. Designing new aluminum alloys that can be processed crack-free by Laser Powder Bed Fusion (L-PBF) while exhibiting comparable or enhanced mechanical properties is a major target, which may be reached by including in the alloy design strategy specific features of this processing route such as the very high cooling rates. Here, we study a novel Al-4Mn-3Ni-2Cu-2Zr alloy processed by L-PBF, which shows some specific features in comparison to other Al-alloys developed for additive manufacturing. We establish the relationships between the processing conditions and the specific features of the microstructure inherited from L-PBF based on a multi-scale microstructural characterization approach from the melt pool scale up to the nanoscale using X-ray diffraction and electron microscopy with a special focus on Automated Crystal Orientation Mapping (ACOM) in transmission. At the melt pool scale, three regions have been identified: FEZ (Fine Equiaxed Zone), CZ (Columnar Zone) and CEZ (Coarse Equiaxed Zone) giving a hierarchical architecture to the microstructure. Each region has been thoroughly characterized by coupling ACOM and chemical mapping. Five different intermetallic phases have been identified in the as-built microstructure: Al3Zr, Al3Ni2, Al9Ni2, Al60 Mn 11Ni 14, and Al2Cu. The spatial distribution of these intermetallic phases has been found to vary within a given molten pool. The solidification sequence and the various mechanisms involved in the formation of this peculiar microstructure are discussed in the light of our multi-scale microstructural observations along with solidification thermodynamic calculations.