Further Improvements in AlMgSc (Scalmalloy®) Alloy Concepts for LPB-F by (unusual) Ca-Additions

Laser powderbed fusion (LPB-F) direct additive manufacturing has demonstrated new capabilities for tailored Al-material concepts highlighted by 500 MPa+ AlMgSc (“Scalmalloy®) due to its intrinsic particular solidification condition. Using non-heated build-platforms many investigations are indicating that the tiny melt puddle during LPB-F will solidify with cooling speed up to 10⁵ – 10⁶ K/sec. Such rapid cooling boundary conditions favor new alloying concepts for Al-alloys which were uninteresting in classical metal engineering due to pronounced solution limits and/or undesired primary phase creation. Calcium is a promising element because it has a lower density than Mg however its melting & evaporation behavior fits better to laser (melting) processing. The presentation will show 1^st results how Ca is affecting a high strength AlMgSc alloys in term of LPB-F process propensities as well overall strength evolution.