Achieving high strength in laser powder-bed fusion processed AlFeCuZr alloy via dual-nanoprecipitations and grain boundary segregation

•A novel crack-free and near-full dense Al-Fe-Cu-Zr alloy was designed for LPBF.•It exhibits heterogeneous microstructures with coarse-grain zones (CGZs) and fine-grain zones (FGZs).•(Al, Cu)Fe3 nanoparticles precipitated in the CGZs, Fe and Cu co-segregated at the grain boundaries (GBs).•Al3Zr nanoparticles precipitated in the FGZs, Fe-rich nano-precipitates and Fe/Cu co-segregation appeared at GBs.•The as-printed AlFeCuZr alloy demonstrated a high yield strength of 500 MPa at room temperature and 163 MPa at 573 K.