Processability of high strength Aluminum-Copper alloys AW-2022 and 2024 by Laser Beam Melting in Powder Bed

Additive Manufacturing offers geometric freedom excellently suited for topology optimized light weight designs. Ideally these should be produced from materials of high strength to weight ratio such as aluminium-copper alloys. Yet these are considered unsuitable for welding. With Laser Beam Melting of Metals in powder bed (LBM), the only class of aluminium alloys widely processed is that of aluminium-silicon alloys, which are easily weldable and castable, too. In this contribution we present results of LBM high-strength aluminium-copper alloys AW-2022 and AW-2024 under variation of laser power, scan speed and hatch distance. We achieved relative densities well above 99 %. We analyzed thin walls, compared process windows as well as microstructures observed using etched metallographic microsections. We analyzed the chemical constitution of powders and produced samples using ICP-OES.