Optimization of Post-Processing Heat Treatment for an High-Performance Aerospace Grade Aluminum Alloy Manufactured by Laser Powder Bed Fusion (LPBF)

Achieving high-performance components produced through Additive Manufacturing (AM) requires tailored post-processing treatments due to the distinct microstructure formed during the AM process, which differs significantly from that of traditional casting. The incorporation of inoculants and reinforcement materials further complicates the microstructure, resulting in unique responses to heat treatments. This study explores the effects of various T6 heat treatment combinations on a 2024 RAM2 aluminum alloy composite reinforced with titanium and ceramic particles. Some heat treatment conditions yielded microhardness values exceeding 200 HV, with shorter solubilization times and lower aging temperatures proving most effective. Microstructural analysis revealed the dissolution of the as-built melt pool structure and the formation of key precipitates, such as Al₂Cu, Al₆Mn, and Al₇Cu₂Fe, in both spherical and needle-like morphologies. These fine precipitates played a critical role in enhancing mechanical properties through mechanisms like precipitation hardening and the Orowan effect.