Innovative Processing Techniques for Additive Manufacture of 7000 Series Aluminum Alloy Components

By using a combination of a highly Gaussian laser beam source, wavelength beam combining and multiple laser beam energy (MBE) PINE and Missouri S&T have successfully demonstrated the ability to create and stabilize Meltpools on all aluminum alloys investigated in Phase I. The MBE system has successfully processed several aluminum alloys with the potential to meet the performance needs of replacing 7000 series alloys. The use of MBE enables the removal of oxide layers, contaminants and other Meltpool ejecta from the immediate environment of the deposition, leading to clean deposition surfaces and excellent metallurgical bonds. MBE also creates a secondary solidification front that alters cooling rates. By slowing down the cooling rates some of the problems associated with the rapid cooling and solidification of aluminum alloys can be mitigated. Phase II will involve the construction of a MBE DED system that will process aluminum alloys with minimal defects. ASTM E8, and microstructural characterization will demonstrate the performance of the as-deposited alloys and post process heat treatments will improve them. Additional unique features include the ability to blend materials and achieve GD&T, each of which offer possible minimization in powder preparation and post processing needs that other processes don’t.