Composition design method of Al-Cu alloy for laser powder bed fusion

In this study, Al-Cu alloy suitable for laser powder bed fusion (LPBF) is rapidly developed through casting and laser remelting. The microstructure of as-cast Al-Cu alloy is consisted of equiaxed grains, and it was significantly refined after remelting. The Vickers hardness in the remelted zone improved by approximately 33.7% compared with that of as-cast Al-Cu alloy. The effects of different element content on Al-Cu-Mg-Zr alloy were analyzed, and optimum alloy composition was obtained with Al-5Cu-2Mg-1Zr-0.3Mn-0.15Ti through comparing microstructure, the hardness and other properties after remelting. The nano-indentation hardness and Young’s modulus of remelted Al-5Cu-2Mg-1Zr-0.3Mn-0.15Ti alloys were 1.86 and 86.7 GPa, respectively. The microstructure was dense without obvious crack after LPBF forming, and the tensile strength, yield strength and elongation values reach 483 MPa, 365 MPa and 13.4% after solution treatment. •The suitability of LPBF-fabricated alloys composition was judged by cast and laser remelting..•The ultra-fine microstructure and Al2Cu dispersion distribution were observed in laser remelting alloy.•New composition Al-Cu alloy prepared by LPBF shows a dense structure and good mechanical behavior.