Aluminum alloys, known for their high strength-to-weight ratios and impressive electrical and thermal conductivities, are extensively used in numerous engineering sectors, such as aerospace, automotive, and construction. Recently, significant efforts have been made to develop novel aluminum alloys specifically tailored for additive manufacturing. These new alloys aim to provide an optimal balance between mechanical properties and thermal/ electrical conductivities. In this study, nine combinatorial samples with various alloy compositions were fabricated using direct energy deposition (DED) additive manufacturing by adjusting the feeding speeds of Al6061 alloy and Al-12Si alloy powders. The effects of the alloying elements on the microstructure, electrical conductivity, and hardness were investigated. Generally, as the Si and Cu contents decreased, electrical conductivity increased and hardness decreased, exhibiting trade-off characteristics. However, electrical conductivity and hardness showed an optimal combination when the Si content was adjusted to below 4.5 wt%, which can sufficiently suppress the grain boundary segregation of the α- Si precipitates, and the Cu content was controlled to induce the formation of Al2Cu precipitates.

Aluminum alloys are extensively employed in several industries, such as automobile, aerospace, and architecture, owing to their high specific strength and electrical and thermal conductivities. However, to meet the rising industrial demands, aluminum alloys must be designed with both excellent mechanical and thermal properties. Computer-aided alloy design is emerging as a technique for developing novel alloys to overcome these trade-off properties. Thus, the development of a new experimental method for designing alloys with high-throughput confirmation is gaining focus. A new approach that rapidly manufactures aluminum alloys with different compositions is required in the alloy design process. This study proposes a combined approach to rapidly investigate the relationship between the microstructure and properties of aluminum alloys using a direct energy deposition system with a dual-nozzle metal 3D printing process. Two types of aluminum alloy powders (Al-4.99Si-1.05Cu-0.47Mg and Al-7Mg) are employed for the 3D printing-based combined method. Nine types of Al-Si-Cu-Mg alloys are manufactured using the combined method, and the relationship between their microstructures and properties is examined.

본 논문에서는 해양플랜트에 주로 사용되는 알루미늄 사다리의 독자 모델을 개발하기 위하여, 개량형 알루미늄 합금(6082-T6) 을 적용하고 국제 기준에 부합한 구조강도 설계를 하였다. 국제기준은 ISO, NORSOK, Austria Standard를 참고하였으며, 모든 조건이 만족할 수 있도록 하중 조합을 하였다. 설계된 모델은 유한요소법 [Finite elements method]을 근간으로 하는 해양플랜트 전용 해석프로그램인 SACS를 사용하여 구조 안전성을 검증하여 응력 및 처짐이 모두 허용기준 이내에 만족함을 확인하였다. 개발모델은 모든 허용기준을 만족하면서도 가볍고, 생산성이 향상되어 향후 많은 분야에서 사용이 될 것으로 기대해본다.

본 논문에서는 탄소성 영역 내 패치 로딩 크기에 따른 알루미늄 합금 사각형 판의 초기 처짐 영향을 수치해석방법으로 이용한 탄성 및 탄소성 대변형 시리즈 해석을 수행하였다. 주변 지지조건은 단순지지로 가정하고 초기 처짐 크기(w/t), 종횡비(a/b), 세장비(b/t)를 고려하여 알루미늄 합금 A6082-T6 사각형 판의 임계 탄성 좌굴하중과 좌굴 후 거동을 검토하였다. 탄성 및 탄소성 대변형 시리즈 해석은 상용프로그램을 사용하였다. 초기 처짐 크기가 작을 경우 하중증가와 함께 면내 강성이 처음부터 감소하며 크기가 커질수록 훨씬 두드러지게 발생한다. 종횡비가 커질수록 초기항복강도는 점차 감소하며 판 두께가 두꺼울수록 패치 로딩 크기(l/b) 0.5 이후 초기 항복강도 감소비율은 얇은 두께보다 더 크게 발생한다.