Enhanced Strength and Hardness of AS41 Magnesium Alloy Fabricated by Selective Laser Melting

AS41 magnesium alloy possesses outstanding performance features such as light weight, high strength to toughness ratio and excellent heat resistance due to the addition of Si element, while traditional casting methods are prone to inducing large grain size and coarse Mg₂Si phase. In this study, we first reported utilizing the selective laser melting (SLM) technique, fabricating AS41 samples and exploring the effect of laser energy densities on the metallurgical quality by characterizing and investigating the microstructure and mechanical properties. Results showed that the optimal laser energy density range was 60 to 100 J/mm³. Average grain size of only 2.9 μm was obtained with weak texture strength of 1.65 in {0001} orientation. Meanwhile, many dispersed secondary β-Mg₁₇Al₁₂ and Mg₂Si phases were distributed inside the α-Mg matrix. It was confirmed that the SLM process introduced more grain recrystallization, inducing giant high-angle grain boundaries (HAGBs) and hindering the movement of dislocations, therefore forming dislocation strengthening while achieving grain refinement strengthening. Finally, three times the ultimate tensile strength of 313.7 MPa and higher microhardness of 96.4 HV than those of the as-cast state were obtained, verifying that the combined effect of grain refinement, solid solution strengthening and precipitation strengthening was responsible for the increased strength. This work provides new insight and a new approach to preparing AS41 magnesium alloy.