Enhancing the Mechanical Properties of Al-Si Alloy Fabricated by Selective Laser Melting by Doping Trace Rare Earth Elements
SHI Qifeng1, YANG Tao1, QI Liang1, HAO Jingyan1, WU Huishu1,2,*, LI Runxia3
1 School of Mechanical Engineering, Tongling University, Tongling 244002, Anhui, China 2 College of Materials Science and Engineering, University of Science and Technology of China, Hefei 230026, China 3 School of Materials Science and Engineering, Dongguan University of Technology, Dongguan 523808, Guangdong, China
Abstract: To address the persistent challenges in selective laser melting (SLM) processing of AlSi10Mg alloy (inherent limitations of high laser reflectivity in AlSi10Mg powder and sub-optimal mechanical properties), an AlSi10Mg-Er alloy was designed with rare earth element Er as an additive. The microstructure and mechanical behavior of the AlSi10Mg-Er alloy were investigated systematically. Results revealed that the incorporation of Er substantially improves laser energy absorption in AlSi10Mg powder, resulting in an increase in the molten pool temperature. This thermal enhancement generates an increased undercooling, thereby amplifying the solidification driving force and facilitating significant grain refinement. In addition, Er distributed along the boundaries of the network-like Si phase as Al3Er precipitates, which act as heterogeneous nucleation sites to refine the grain and have a pinning effect through dispersion strengthening. Notably, the addition of Er was also observed to refine the continuous network structure of the Si phase, resulting in a more fragmented morphology. Under the synergistic effects of grain refinement and precipitation strengthening (Al3Er and Si precipitates), the mechanical properties have improved remarkably. Tensile testing demonstrates concurrent enhancement of strength and ductility, with ultimate tensile strength and elongation increasing by 9.5% and 9.3%, respectively. Compressive strength also shows a 4.6% improvement.
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2026, Vol. 40 
