Novel high specific-strength multi-topology Al-Ni-Ti-Zr-Mn alloy using laser powder bed fusion additive manufacturing
Additive manufacturing has opened a paradigm for the efficient and quick production of lightweight lattice structures showing characteristic high specific strength (strength-to-weight ratios). The current study describes the development of methodology and utilization of high strength Al alloy for bu...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-07-01
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| Series: | Additive Manufacturing Letters |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2772369025000416 |
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| author | Amit Kumar Singh Prithvi D. Awasthi Ankita Roy Priyanka Agrawal Aishani Sharma Anurag Gumaste Ravi Sankar Haridas Rajiv S. Mishra |
| author_facet | Amit Kumar Singh Prithvi D. Awasthi Ankita Roy Priyanka Agrawal Aishani Sharma Anurag Gumaste Ravi Sankar Haridas Rajiv S. Mishra |
| author_sort | Amit Kumar Singh |
| collection | DOAJ |
| description | Additive manufacturing has opened a paradigm for the efficient and quick production of lightweight lattice structures showing characteristic high specific strength (strength-to-weight ratios). The current study describes the development of methodology and utilization of high strength Al alloy for building complex lattice using additive manufacturing. Thin plate lattice <1 mm of Al-Ni-Ti-Zr-Mn alloy with wide processing window, achieving an average yield strength of 63.13±3.32 MPa in compression, with 28 % lower density than Ti-6Al-4V demonstrates a successful design of Al-Ni-Ti-Zr-Mn alloys using laser beam powder bed fusion (PBF-LB). The mitigation of cracks within thin plate parallel to the loading axis was achieved through the formation of Al-Al₃Ni eutectic channels, exploiting the rapid solidification of this short-freezing-range alloy. In addition to multi-topology structural design, the enhanced strength is attributed to hierarchical microstructure featuring L1₂ phases, bimodal grain distribution, and solid solution strengthening by Mn. This work establishes a printability-performance synergy of Al-Ni-Ti-Zr-Mn alloy for thin plate complex lattice, advancing the use of metamaterials through PBF-LB. |
| format | Article |
| id | doaj-art-0cd5ebb2a3fd4e5fba6ce8b157b2ce9f |
| institution | Kabale University |
| issn | 2772-3690 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Additive Manufacturing Letters |
| spelling | doaj-art-0cd5ebb2a3fd4e5fba6ce8b157b2ce9f2025-08-21T04:17:56ZengElsevierAdditive Manufacturing Letters2772-36902025-07-011410030810.1016/j.addlet.2025.100308Novel high specific-strength multi-topology Al-Ni-Ti-Zr-Mn alloy using laser powder bed fusion additive manufacturingAmit Kumar Singh0Prithvi D. Awasthi1Ankita Roy2Priyanka Agrawal3Aishani Sharma4Anurag Gumaste5Ravi Sankar Haridas6Rajiv S. Mishra7Center for Agile and Adaptive Additive Manufacturing, University of North Texas, Denton, TX 76207, USA; Center for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USA; Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USACenter for Agile and Adaptive Additive Manufacturing, University of North Texas, Denton, TX 76207, USA; Center for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USA; Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USACenter for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USA; Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USACenter for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USA; Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USACenter for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USA; Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USACenter for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USA; Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USADepartment of Mechanical Engineering, University of North Texas, Denton, TX 76207, USACenter for Agile and Adaptive Additive Manufacturing, University of North Texas, Denton, TX 76207, USA; Center for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USA; Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USA; Corresponding author.Additive manufacturing has opened a paradigm for the efficient and quick production of lightweight lattice structures showing characteristic high specific strength (strength-to-weight ratios). The current study describes the development of methodology and utilization of high strength Al alloy for building complex lattice using additive manufacturing. Thin plate lattice <1 mm of Al-Ni-Ti-Zr-Mn alloy with wide processing window, achieving an average yield strength of 63.13±3.32 MPa in compression, with 28 % lower density than Ti-6Al-4V demonstrates a successful design of Al-Ni-Ti-Zr-Mn alloys using laser beam powder bed fusion (PBF-LB). The mitigation of cracks within thin plate parallel to the loading axis was achieved through the formation of Al-Al₃Ni eutectic channels, exploiting the rapid solidification of this short-freezing-range alloy. In addition to multi-topology structural design, the enhanced strength is attributed to hierarchical microstructure featuring L1₂ phases, bimodal grain distribution, and solid solution strengthening by Mn. This work establishes a printability-performance synergy of Al-Ni-Ti-Zr-Mn alloy for thin plate complex lattice, advancing the use of metamaterials through PBF-LB.http://www.sciencedirect.com/science/article/pii/S2772369025000416Additive manufacturingAluminium alloyLaser powder bed fusionGibson-Ashby modelLattice structuresMetamaterials |
| spellingShingle | Amit Kumar Singh Prithvi D. Awasthi Ankita Roy Priyanka Agrawal Aishani Sharma Anurag Gumaste Ravi Sankar Haridas Rajiv S. Mishra Novel high specific-strength multi-topology Al-Ni-Ti-Zr-Mn alloy using laser powder bed fusion additive manufacturing Additive Manufacturing Letters Additive manufacturing Aluminium alloy Laser powder bed fusion Gibson-Ashby model Lattice structures Metamaterials |
| title | Novel high specific-strength multi-topology Al-Ni-Ti-Zr-Mn alloy using laser powder bed fusion additive manufacturing |
| title_full | Novel high specific-strength multi-topology Al-Ni-Ti-Zr-Mn alloy using laser powder bed fusion additive manufacturing |
| title_fullStr | Novel high specific-strength multi-topology Al-Ni-Ti-Zr-Mn alloy using laser powder bed fusion additive manufacturing |
| title_full_unstemmed | Novel high specific-strength multi-topology Al-Ni-Ti-Zr-Mn alloy using laser powder bed fusion additive manufacturing |
| title_short | Novel high specific-strength multi-topology Al-Ni-Ti-Zr-Mn alloy using laser powder bed fusion additive manufacturing |
| title_sort | novel high specific strength multi topology al ni ti zr mn alloy using laser powder bed fusion additive manufacturing |
| topic | Additive manufacturing Aluminium alloy Laser powder bed fusion Gibson-Ashby model Lattice structures Metamaterials |
| url | http://www.sciencedirect.com/science/article/pii/S2772369025000416 |
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