Microstructure evolution and mechanical properties of laser directed energy deposited Al 2024 alloy

Yanfang Wang; Shikui Huang; Chengyu Ma; Chengen Wang; Yihui Jiang; Yufan Zhao; Xin Lin

doi:10.1016/j.matchar.2025.115482

Microstructure evolution and mechanical properties of laser directed energy deposited Al 2024 alloy

Yanfang Wang
, Shikui Huang
, Chengyu Ma
, Chengen Wang
, Yihui Jiang
, Yufan Zhao
, Xin Lin

School of Materials Sience and Engineering

Xi'an University of Technology
Ministry of Education of the People's Republic of China
Shaanxi Province Key Laboratory of Electrical Materials and Infiltration Technology
Northwestern Polytechnical University Xian

Research output: Contribution to journal › Article › peer-review

1 Scopus citations

Abstract

Laser-directed energy deposition (L-DED) has emerged as a promising technique for manufacturing high-performance aluminum alloy components with complex geometries and large dimensions. In this work, L-DEDed Al 2024 samples in straight wall scale were deposited first to optimize process parameters, then the bulk deposits were prepared on this basis. The microstructural analysis of both straight walls and bulk sample was performed. The analysis shows that the primary dendrite spacing in the last layer of straight walls increases with the deposited layer number increasing, due to the decreased temperature gradient caused by significant heat accumulation. The bulk sample exhibited a fully columnar grain structure, consisting of α-Al + Al₂Cu/Al₂CuMg eutectic phases, Mg₂Si and Al₇Cu₂(Fe, Mn) dispersoids, along with in-situ formed secondary θ (Al₂Cu) and S (Al₂CuMg) precipitates. Benefiting from the combination of dispersion strengthening and precipitation strengthening mechanisms, the yield strength of 159 ± 30 MPa and ultimate tensile strength of 280 ± 22 MPa were achieved in the L-DEDed Al 2024 alloy.

Original language	English
Article number	115482
Journal	Materials Characterization
Volume	229
DOIs	https://doi.org/10.1016/j.matchar.2025.115482
State	Published - Nov 2025

Keywords

Additive manufacturing
Al-Cu-Mg alloy
Laser directed energy deposition
Microstructure
Tensile properties

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10.1016/j.matchar.2025.115482

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title = "Microstructure evolution and mechanical properties of laser directed energy deposited Al 2024 alloy",

abstract = "Laser-directed energy deposition (L-DED) has emerged as a promising technique for manufacturing high-performance aluminum alloy components with complex geometries and large dimensions. In this work, L-DEDed Al 2024 samples in straight wall scale were deposited first to optimize process parameters, then the bulk deposits were prepared on this basis. The microstructural analysis of both straight walls and bulk sample was performed. The analysis shows that the primary dendrite spacing in the last layer of straight walls increases with the deposited layer number increasing, due to the decreased temperature gradient caused by significant heat accumulation. The bulk sample exhibited a fully columnar grain structure, consisting of α-Al + Al2Cu/Al2CuMg eutectic phases, Mg2Si and Al7Cu2(Fe, Mn) dispersoids, along with in-situ formed secondary θ (Al2Cu) and S (Al2CuMg) precipitates. Benefiting from the combination of dispersion strengthening and precipitation strengthening mechanisms, the yield strength of 159 ± 30 MPa and ultimate tensile strength of 280 ± 22 MPa were achieved in the L-DEDed Al 2024 alloy.",

keywords = "Additive manufacturing, Al-Cu-Mg alloy, Laser directed energy deposition, Microstructure, Tensile properties",

author = "Yanfang Wang and Shikui Huang and Chengyu Ma and Chengen Wang and Yihui Jiang and Yufan Zhao and Xin Lin",

note = "Publisher Copyright: {\textcopyright} 2025 Elsevier Inc.",

year = "2025",

month = nov,

doi = "10.1016/j.matchar.2025.115482",

language = "英语",

volume = "229",

journal = "Materials Characterization",

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TY - JOUR

T1 - Microstructure evolution and mechanical properties of laser directed energy deposited Al 2024 alloy

AU - Wang, Yanfang

AU - Huang, Shikui

AU - Ma, Chengyu

AU - Wang, Chengen

AU - Jiang, Yihui

AU - Zhao, Yufan

AU - Lin, Xin

PY - 2025/11

Y1 - 2025/11

N2 - Laser-directed energy deposition (L-DED) has emerged as a promising technique for manufacturing high-performance aluminum alloy components with complex geometries and large dimensions. In this work, L-DEDed Al 2024 samples in straight wall scale were deposited first to optimize process parameters, then the bulk deposits were prepared on this basis. The microstructural analysis of both straight walls and bulk sample was performed. The analysis shows that the primary dendrite spacing in the last layer of straight walls increases with the deposited layer number increasing, due to the decreased temperature gradient caused by significant heat accumulation. The bulk sample exhibited a fully columnar grain structure, consisting of α-Al + Al2Cu/Al2CuMg eutectic phases, Mg2Si and Al7Cu2(Fe, Mn) dispersoids, along with in-situ formed secondary θ (Al2Cu) and S (Al2CuMg) precipitates. Benefiting from the combination of dispersion strengthening and precipitation strengthening mechanisms, the yield strength of 159 ± 30 MPa and ultimate tensile strength of 280 ± 22 MPa were achieved in the L-DEDed Al 2024 alloy.

AB - Laser-directed energy deposition (L-DED) has emerged as a promising technique for manufacturing high-performance aluminum alloy components with complex geometries and large dimensions. In this work, L-DEDed Al 2024 samples in straight wall scale were deposited first to optimize process parameters, then the bulk deposits were prepared on this basis. The microstructural analysis of both straight walls and bulk sample was performed. The analysis shows that the primary dendrite spacing in the last layer of straight walls increases with the deposited layer number increasing, due to the decreased temperature gradient caused by significant heat accumulation. The bulk sample exhibited a fully columnar grain structure, consisting of α-Al + Al2Cu/Al2CuMg eutectic phases, Mg2Si and Al7Cu2(Fe, Mn) dispersoids, along with in-situ formed secondary θ (Al2Cu) and S (Al2CuMg) precipitates. Benefiting from the combination of dispersion strengthening and precipitation strengthening mechanisms, the yield strength of 159 ± 30 MPa and ultimate tensile strength of 280 ± 22 MPa were achieved in the L-DEDed Al 2024 alloy.

KW - Additive manufacturing

KW - Al-Cu-Mg alloy

KW - Laser directed energy deposition

KW - Microstructure

KW - Tensile properties

UR - https://www.scopus.com/pages/publications/105013523138

U2 - 10.1016/j.matchar.2025.115482

DO - 10.1016/j.matchar.2025.115482

M3 - 文章

AN - SCOPUS:105013523138

SN - 1044-5803

VL - 229

JO - Materials Characterization

JF - Materials Characterization

M1 - 115482

ER -

Microstructure evolution and mechanical properties of laser directed energy deposited Al 2024 alloy

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Keywords

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