Aluminum Alloy Laminated Molding Alpha Phase Control
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Solution Overview
Problem
The mechanical strength and malleability of aluminum alloy laminated moldings are compromised due to the formation of brittle β-phase Al—Si—Fe metal intermetallic compounds during manufacturing, which are planar and monoclinic in structure, leading to reduced performance.
Innovation Solution
An aluminum alloy containing Si, Fe, Mn, and inevitable impurities with a focus on promoting the formation of α-phase Al—Si—Fe intermetallic compounds, which are cubic and granular, thereby suppressing the growth of β-phase compounds and enhancing malleability, and optionally including Be or Zr to further improve properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aluminum alloy contains Si and Fe, then mechanical strength is improved, but malleability declines due to β-phase Al-Si-Fe intermetallic compound growth
Solution Approach 1:
The invention changes the chemical composition parameters by adding Mn (0.05-7 mass%) and controlling Si (3-20 mass%) and Fe (0.5-7 mass%) content. This parameter change transforms the intermetallic compound phase from brittle β-phase to α-phase, which has different crystal structure characteristics that improve malleability while maintaining strength
Solution Approach 2:
The invention creates a composite microstructure containing α-phase Al-Si-Fe intermetallic compounds dispersed in the aluminum matrix. This composite structure combines the strength benefits of intermetallic compounds with the malleability of the aluminum matrix, resolving the contradiction between strength and formability
2Strength
If β-phase Al-Si-Fe intermetallic compound grows during manufacturing, then mechanical strength increases, but the alloy becomes brittle due to monoclinic crystal structure
Solution Approach 1:
By adding Mn and controlling the Si-Fe-Mn composition ratio, the invention changes the thermodynamic parameters that govern phase formation. This causes the α-phase to form instead of the β-phase during solidification, resulting in a cubic crystal structure that is less brittle while maintaining mechanical strength
Solution Approach 2:
The invention exploits phase transition phenomena during solidification by controlling composition to favor α-phase formation. The α-phase Al-Si-Fe intermetallic compound has a cubic crystal structure that transitions during cooling, creating a microstructure that maintains strength while reducing brittleness compared to the monoclinic β-phase
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The presence of α-phase Al—Si—Fe intermetallic compounds improves malleability and mechanical strength, while also enhancing corrosion resistance, and allows for the use of secondary aluminum alloys with reduced environmental impact, as evidenced by increased stretch and improved tensile testing results.
Implementation Method 1
a process of solidification is repeated after spreading aluminum alloy powder and dissolving aluminum alloy powder by irradiating a laser beam or electron beam onto a specific site
Implementation Method 2
a process of solidification is repeated after spreading aluminum alloy powder and dissolving aluminum alloy powder by irradiating a laser beam or electron beam onto a specific site
Implementation Method 3
a process of solidification is repeated after spreading aluminum alloy powder and dissolving aluminum alloy powder
Data Source
AI summary
The present disclosure provides an aluminum alloy to be used in laminate molding containing Si, Fe, Mn and inevitable impurities, in which α-phase Al—Si—Fe intermetallic compound is present in the aluminum alloy. In addition, a manufacturing method of a laminated molding is provided which laminate molds using powder of this aluminum alloy. Further, a laminate molding of this aluminum alloy is provided.