Effect of processing parameters on solidification defects behavior of laser deposited AlSi10Mg alloy

Gao, Yuan; Zhao, Jibin; Zhao, Yuhui; Wang, Zhiguo; Song, Hong-Wu; Gao, Mengqiu

doi:10.1016/j.vacuum.2019.06.042

Cited by 29 publications

(11 citation statements)

References 23 publications

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“…The authors concluded that the optimal laser beam energy density range to melt AlSi10Mg powder is 50–60 J/mm 3 , as this minimizes the occurrence of pores in the structure. Similar conclusions were reached by Trevisan et al [ 14 ] and Gao et al [ 15 ].…”

Section: Introductionsupporting

confidence: 90%

Surface Topographic Features after Milling of Additively Manufactured AlSi10Mg Aluminum Alloy

Struzikiewicz

Sioma

2022

Materials

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The article presents selected issues related to material quality manufactured by selective laser sintering of AlSi10Mg alloy powder after milling. The workpiece was prepared and machined by down-milling and up-milling with tools made of high-speed steel. Breaches, pores and failure-like cracks on the machined surface were found, which negatively influenced the values of 3D surface roughness parameters. The occurring phenomena were analyzed and proposals for their explanation were made. The results of this research describe the effect of cutting parameters (the feed rate of f = 0.013–0.05 mm/tooth) on the values of parameters describing the surface quality and benchmarks. Topography measurements and 3D surface roughness parameters are presented, as well as the results of microscopic surface analysis. It was found that for aluminum alloy produced by the direct metal laser sintering (DMLS) method, the recommended machining method is down-milling.

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Section: Introductionsupporting

confidence: 90%

Surface Topographic Features after Milling of Additively Manufactured AlSi10Mg Aluminum Alloy

Struzikiewicz

Sioma

2022

Materials

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“…The high thermal expansivity and large solidification range of Al alloy could induce a large amount of residual stress at a high cooling rate and tend to cause solidification cracks due to solidification shrinkage [65,66]. Overall, Al-Si alloys' solidification ranges and thermal expansivity are relatively low, as shown in figures 3(b)-(d) [34,[67][68][69][70][71]. Therefore, most of the research on LDED Al alloys is around Al-Si alloys, especially the traditionally cast AlSi10Mg and AlSi7Mg alloys, whose printability and castability are excellent.…”

Section: High Thermal Expansivity and Large Solidification Rangementioning

confidence: 98%

“…Therefore, most of the research on LDED Al alloys is around Al-Si alloys, especially the traditionally cast AlSi10Mg and AlSi7Mg alloys, whose printability and castability are excellent. However, the room-temperature strength of as-deposited and heat-treated Al-Si alloys is not high enough to meet industrial requirements, and their poor deformability also limits diversified applications [54,67,68,72]. Wrought Al alloys, such as Al-Cu, Al-Mg and Al-Zn alloys, possess a wider solidification temperature range, higher crack sensitivity, high probability of alloying elements evaporating, and inferior printability, but their excellent mechanical properties offer them great research value.…”

Section: High Thermal Expansivity and Large Solidification Rangementioning

confidence: 99%

“…Porosities. The primary causes of porosities in LDED Al alloys involve (i) keyhole pores caused by excessive laser energy input; (ii) irregular-shaped lack-of-fusion pores due to insufficient laser energy input; (iii) metallurgical pores originated from gas entrapment into the melt pool; and (iv) porosities inherited from the feedstock [57,68,[82][83][84].…”

Section: 31mentioning

confidence: 99%

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Review on laser directed energy deposited aluminum alloys

Liu,

Chen,

Qiu

et al. 2024

Int. J. Extrem. Manuf.

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The lightweight aluminum (Al) alloys have been widely used in frontier fields like aerospace and automotive industries, which attracts great interest in additive manufacturing to process high-value Al parts. As a mainstream additive manufacturing technique, laser directed energy deposition (LDED) shows good scalability to meet requirements for large-format components manufacturing and repairing. However, LDED Al alloys are highly challenging due to the inherent poor printability (e.g., low laser absorption, high oxidation sensitivity and cracking tendency). To further promote the development of LDED high-performance Al alloys, this review gains a deep understanding of the challenges and strategies to improve printability in LDED Al alloys. The porosity, cracking, distortion, inclusions, elements evaporation and resultant inferior mechanical properties (than laser powder bed fusion) are the key challenges in LDED Al alloys. Processing parameter optimizations, in-situ alloy design, reinforcing particle addition and field assistance are the efficient approaches to improve the printability and performance of LDED Al alloys. The underlying correlations between processes, alloy innovation, characteristic microstructures, and achievable performances in LDED Al alloys are discussed. The benchmarking mechanical properties and primary strengthening mechanism of LDED Al alloys are summarized. This review aims to provide a critical and in-depth evaluation of current progress in LDED Al alloys. The future opportunities and perspectives in LDED high-performance Al alloys are also outlooked.

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“…LAM technology can realize the direct deposition manufacture of dissimilar materials, add transition layer connection and gradient transition connection, etc [21], which broadens the connection method of dissimilar materials and provides new possibilities for the connection of dissimilar materials. Up to now, there are many researches on the LAM technology of individual aluminum alloys or individual titanium alloys [22][23][24][25][26][27], but there are few research reports on the connection of titanium alloys and aluminum alloy dissimilar materials through the LAM technology.…”

Section: Introductionmentioning

confidence: 99%

Microstructure and mechanical properties of transition zone in laser additive manufacturing of TC4/AlSi12 bimetal structure

Jing

Liu²,

Wang

et al. 2022

Mater. Res. Express

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Ti/Al bimetallic structure (BS) has a good development prospect and broader application potential in aerospace engineering. Considering the limitation that dissimilar welding is only applicable to the thin plate, it is necessary to explore a new manufacturing process for Ti/Al BS. In this study, a TC4/AlSi12 BS was prepared by laser additive manufacturing (LAM). TC4 zone, AlSi12 zone and transition zone were formed in the LAM process. Due to the sufficient diffusion reaction, the transition zone with a width of about 0.8mm was obtained. At the same time, a few micro-cracks were found in the transition zone. The microstructure and phase composition of the transition zone had been emphatically studied. Research results showed that the presence of Si element made the phase composition of the transition zone more complicated. The structure evolution from TC4 to AlSi12 was: α-Ti → Ti3Al → TiAl+(TiAl+Si) → Ti5Si3 → TiAl3+(α-Al+Si) → α-Al+ Si +TiAl3 +(α-Al+Si) → α-Al+Si+(α-Al+Si). The hardness distribution of BS was uneven, with the highest value reaching 524HV. The tensile strength of the TC4/AlSi12 BS was about 110Mpa, and the fracture location was located in the transition zone.

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Effect of processing parameters on solidification defects behavior of laser deposited AlSi10Mg alloy

Cited by 29 publications

References 23 publications

Surface Topographic Features after Milling of Additively Manufactured AlSi10Mg Aluminum Alloy

Surface Topographic Features after Milling of Additively Manufactured AlSi10Mg Aluminum Alloy

Review on laser directed energy deposited aluminum alloys

Microstructure and mechanical properties of transition zone in laser additive manufacturing of TC4/AlSi12 bimetal structure

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