Optimizing Heat Treatment for Printed Aluminum

The Challenge

AlSi7Mg and AlSi10Mg are among the most widely used aluminum alloys in metal additive manufacturing, but parts produced by laser powder bed fusion (LPBF) contain significant residual stresses and non-equilibrium microstructures. Understanding how heat treatment affects the complex interrelationship between process parameters, microstructure evolution, and final mechanical properties is essential for optimizing post-processing procedures—yet traditional destructive testing provides only snapshots, not the continuous monitoring needed to track these transformations.

The Solution

This research employed three complementary thermo-physical characterization techniques to monitor microstructural changes during heat treatment. Electrical resistivity tracked the evolution of dissolved silicon in the aluminum matrix. Differential scanning calorimetry captured precipitation reactions. Impulse excitation testing measured elastic property changes and damping behavior throughout the heat treatment cycle.

The IET measurements proved particularly valuable, providing non-destructive, real-time feedback on how elastic modulus and internal friction evolved as the microstructure transformed. This continuous monitoring revealed the characteristic signatures of different precipitation stages and stress relief mechanisms, enabling direct correlation between heat treatment parameters and property outcomes.

Results

The combined characterization approach successfully linked microstructural evolution to the phenomena captured by each technique, establishing clear relationships between heat treatment conditions and final properties. This methodology enables manufacturers to optimize stress relief cycles for LPBF aluminum alloys while understanding exactly how and when critical transformations occur during thermal processing.