Lighter components through additive manufacturing of aluminum alloys

Important results from the project

The objective of the project has been production of "lighter products with better mechanical performance" by using laser powder bed fusion processing for manufacturing high strength aluminium parts. This goal has been reached in two main ways. First, by improving the microstructure and porosity content of the most widely used aluminium alloy (i.e. AlSi10Mg). Secondly, by developing a new high strength aluminium alloy with a composition which is free from rare earth elements such as Scandium. Hence, this new alloy offers an environmentally friendly alternative to the AM market.

Expected long term effects

An in-depth assessment of the printability of two aluminium alloys in Laser Powder Bed Fusion process has been carried out. The possibilities of lightweight design based on thin wall construction have been thoroughly evaluated. Aspects such as microstructural variability with reducing wall thickness has been investigated. During the project a new high strength aluminium alloy has been developed. This alloy exhibits significantly higher strength than the conventional AlSi10Mg material and thus, it enables further weight reduction without loss of performance.

Approach and implementation

This project has been a close collaboration between different partners across the AM value chain. Höganäs provided know-how in alloy design, supplied powder, and performed mechanical testing. The latest solutions in gas management (from Linde) and, the state-of-the-art hot isostatic pressing equipment (from Quintus) were tested in the project. AMEXCI’s production capacity was utilized for fabrication of parts and, SIS supported the project with the newest developments in standardization. Chalmers and RISE have utilized cutting-edge analytical and experimental tools.