Phase-Field Simulation of Microstructure Formation in Gas-Atomized Al–Cu–Li–Mg Powders

Al–Cu–Li (2xxx series) powders for additive manufacturing processes are often produced by gas atomization, a rapid solidification process. The microstructural evolution of gas-atomized powder particles during solidification was investigated by phase-field simulations using the software tool MICRESS. The following topics were investigated: (1) the microsegregation of copper and lithium in the particle, and the impact of lithium addition on the formation of secondary phases in Al-2.63Cu and Al-2.63Cu-1.56Li systems, (2) the effect of magnesium on the nucleation and final mass fraction of T(1) (Al(2)CuLi) growing from the melt, and (3) the effect of increased magnesium content on the T(1) and Sʹ (AlCu(2)Mg) phase fractions. It is observed that the addition of lithium into the Al–Cu system leads to a decrease in the solid solubility of copper in the primary matrix; consequently, more copper atoms segregate in the interdendritic regions resulting in a greater mass fraction of secondary precipitates. Our result agrees with findings on the beneficial impact of magnesium on the nucleation and precipitation kinetics of T(1) precipitates in the conventional casting process with further thermomechanical heat treatments. Moreover, it is observed that the increase in magnesium from 0.28 wt.% to 0.35 wt.% does not significantly affect the nucleation and the amount of the T(1) phase, whereas a decrease in T(1) phase fraction and a delay of T(1) formation are encountered when magnesium content is further raised to 0.49 wt.%.