The additive manufacture of compositionally graded Al/Cu parts by laser engineered net shaping (LENS) is demonstrated. The use of a blue light build laser enabled deposition on a Cu substrate. The thermal gradient and rapid solidification inherent to selective laser melting enabled mass transport of Cu up to 4 mm away from a Cu substrate through a pure Al deposition, providing a means of producing gradients with finer step sizes than the printed layer thicknesses. Printing graded structures with pure Al, however, was prevented by the growth of Al2Cu3 dendrites and acicular grains amid a matrix of Al2Cu. A combination of adding TiB2 grain refining powder and actively varying print layer composition suppressed the dendritic growth mode and produced an equiaxed microstructure in a compositionally graded part. Material phase was characterized for crystal structure and nanoindentation hardness to enable a discussion of phase evolution in the rapidly solidifying melt pool of a LENS print.
@article{arxiv.2403.19861,
title = {Refining microstructures in additively manufactured Al/Cu gradients through TiB$_2$ inclusions},
author = {Michael J. Abere and Hyein Choi and Levi Van Bastian and Luis Jauregui and Tomas F. Babuska and Mark. A Rodriguez and Frank W. DelRio and Shaun R. Whetten and Andrew B. Kustas},
journal= {arXiv preprint arXiv:2403.19861},
year = {2024}
}