High-strength Al–5Mg₂Si–2Mg–2Fe alloy with extremely high Fe content for green industrial application through additive manufacturing

Achieving superior mechanical properties of Al alloys with high content Fe impurities is very challenging. Here, a feasible method was applied to accommodate (∼2.2 wt.%) and obtain strength in an Al–5Mg2Si–2Mg–2Fe alloy by using additive manufacturing. Heterogeneous distribution Fe, including number density α-Al12(Fe,Mn)3Si particles distributed at the melting pool boundary excessive segregated along cell boundaries that divided Mg2Si eutectics, verified as beneficial factor for design enhancement. In addition heterogeneous grains contain fine cells, interactions between dislocations coherent eutectics played important role improving properties. This work represents breakthrough recycling high-strength extremely doping green industrial application through