Work

Nanoscale 3D characterization of an Al-1Fe-1Zr alloy for additive manufacturing

Year: 2025

Type: article

Abstract: The Al-1Fe-1Zr alloy exploits the non-equilibrium solidification dynamics inherent to laser powder bed fusion, characterized by high thermal gradients and rapid solidification front velocities. Here, we investigate the alloy’s 3D microstructure using state-of-the-art synchrotron-based nano-tomography techniques. High-resolution holographic and near-field ptychographic X-ray computed tomography were employed, achieving spatial resolutions as small as 57 nm. Our comparative analysis shows that near-field ptychographic tomography offers superior signal-to-noise ratio and spatial resolution, while holographic tomography allows for faster data acquisition with minimal loss in quality. These methods reveal the 3D distribution, morphology, and interconnectivity of Fe-rich and Zr-rich intermetallic phases. Complementary X-ray fluorescence computed tomography further provides quantitative local information on elemental concentrations, revealing Fe and Zr distribution with concentration resolutions 1.5 and 3 mg/cm³, respectively. The findings highlight key microstructural features that contribute to the alloy’s enhanced strength and thermal conductivity, offering critical insights for optimizing its performance in LPBF applications.

Source: Materials Characterization

DOI: 10.1016/j.matchar.2025.115109