Features of structure formation in Al–Fe–Mn alloy during crystallization at different cooling rates

The paper studies specific features of the Al–2.5%Fe–1.5%Mn alloy microstructure formation depending on the cooling rate during casting and laser melting. As-cast microstructure analysis showed that with an increase in the cooling rate during crystallization from 0.5 to 940 K/s, the primary crystallization of the Al6(Mn,Fe) phase is almost completely suppressed with the non-equilibrium eutectic volume increasing to 43 %. The Al–2.5%Fe–1.5%Mn alloy microstructure after laser melting features by the presence of dendritic-type aluminum matrix crystals with an average cell size of 0.56 μm surrounded by an iron-manganese phase of eutectic origin with an average plate size of 0.28 μm. The primary crystallization of the Al6(Mn,Fe) phase is completely suppressed. Such a microstructure is formed at cooling rates of 1.1·104 to 2.5·104 K/s, which corresponds to the cooling rates implemented in additive technologies. Regions consisting of Al6(Mn,Fe) phase primary crystals formed by the epitaxial growth mechanism were revealed at the boundary between the track and the base metal and at the remelting boundary. The smaller the eutectic plates and dendritic cell located in the epitaxial layer, the more disperse the primary crystals in the remelting zone. The Al–2.5%Fe–1.5%Mn alloy after laser melting has high hardness at room temperature (93 HV) and good thermal stability after heating up to 300 °C (hardness slightly decreases to 85 HV), and its calculated yield strength is 227 MPa. Combined with the ultra-fine microstructure formed, high processibility during laser melting, hardness at room temperature, and high calculated yield strength, Al–2.5%Fe–1.5%Mn is a promising alloy for use in additive technologies.

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