Fatigue of AlSi10Mg specimens fabricated by additive manufacturing selective laser melting (AM-SLM)

Uzan, Naor Elad; Shneck, R.; Yeheskel, O.; Frage, N.

doi:10.1016/j.msea.2017.08.027

Cited by 256 publications

(105 citation statements)

References 25 publications

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“…The difference can be mainly due to the different process parameters considered in the AM manufacturing process and, accordingly, to the different inclusion size. By taking into account Uzan et al 40 , the fatigue strength at 10 7 cycles (roughness 1.5 μm) is approximately 125 MPa, with a corresponding axial fatigue strength of approximately 90 MPa (loading factor of 0.7), which is very close to the fatigue strength found experimentally in the paper.…”

Section: P-s-n Curvessupporting

confidence: 85%

“…By taking into account Uzan et al, the fatigue strength at 10 7 cycles (roughness 1.5 μm) is approximately 125 MPa, with a corresponding axial fatigue strength of approximately 90 MPa (loading factor of 0.7), which is very close to the fatigue strength found experimentally in the paper.…”

Section: P‐s‐n Curvesmentioning

confidence: 99%

“…Moreover, literature results on tests on AlSi10Mg specimens can be considered for the sake of comparison. In Mower et al 39 and Uzan et al 40 rotating bending fatigue tests were carried out on as-built AlSi10Mg specimens with comparable roughness. In Mower et al 39 , the fatigue strength at 10 7 cycles found experimentally is approximately 90 MPa (roughness 1.5 μm): the corresponding axial fatigue strength is 65 MPa (loading factor of 0.7) and approximately 35% smaller than the fatigue strength found in the present paper.…”

Section: P-s-n Curvesmentioning

confidence: 99%

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VHCF response of as‐built SLM AlSi10Mg specimens with large loaded volume

Tridello

Biffi

Fiocchi

et al. 2018

Fatigue Fract Eng Mat Struct

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It is well known in the literature that fatigue is particularly critical for Additive Manufacturing (AM) parts, because internal defects originating during the AM process represent a critical site for crack initiation. In the literature, the High‐Cycle‐Fatigue (HCF) response of AM parts has been extensively investigated; however, there are few results on the Very‐High‐Cycle‐Fatigue (VHCF) behavior of AM parts, even if the number of machinery components that may sustain VHCF is rapidly increasing in the last years. The present paper investigates the VHCF response of an AlSi10Mg alloy produced through Selective Laser Melting. Ultrasonic tests are carried out on Gaussian specimens with a large loaded volume and show that fatigue failures in VHCF originate from surface and sub‐surface defects with the same mechanism of HCF failures. P‐S‐N curves and fatigue strength at 109 cycles are finally estimated to show the effect of defect size on the VHCF strength. Research highlights Ultrasonic VHCF tests on AlSi10Mg Gaussian specimens produced through SLM. Identification and analysis of critical AM defects inducing VHCF failure. Statistical estimation of models for the prediction of the VHCF response of AM parts. Statistical prediction of effect of defect size on the VHCF response of AM parts.

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Section: P-s-n Curvessupporting

confidence: 85%

Section: P‐s‐n Curvesmentioning

confidence: 99%

Section: P-s-n Curvesmentioning

confidence: 99%

See 1 more Smart Citation

VHCF response of as‐built SLM AlSi10Mg specimens with large loaded volume

Tridello

Biffi

Fiocchi

et al. 2018

Fatigue Fract Eng Mat Struct

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“…Nonetheless, if the viscosity is too low, the melt pool is not stable anymore and balling phenomena are likely to occur [13]. As a term of comparison, the viscosity of aluminum at its melting point (933.5 K) is as low as 1.34 mN·s/m 2 , whereas the viscosity of titanium at its melting point (1958 K) is about three times as much, since it is 4.14 mN·s/m 2 [14].Even if the most common alloys for AM are the hardenable AlSi10Mg (for fatigue behavior, see References [15][16][17][18][19][20][21][22][23][24][25]) and the eutectic AlSi12 [10,[26][27][28], new materials are emerging that require a systematic and coordinated effort to understand their optimal processing conditions and final properties [29,30].A357.0 aluminum, also known as A357 or A13570 (with A357.0 being the Aluminum Association-American National Standards Institute (AA-ANSI) designation for this material [31]), is an aluminum alloy formulated for casting. In view of the approaching release of commercial A357.0 powders for AM, the present contribution is specifically addressed to determine the axial fatigue resistance of A357.0 parts produced by L-PBF and tested in their as-built state.…”

mentioning

confidence: 99%

“…Even if the most common alloys for AM are the hardenable AlSi10Mg (for fatigue behavior, see References [15][16][17][18][19][20][21][22][23][24][25]) and the eutectic AlSi12 [10,[26][27][28], new materials are emerging that require a systematic and coordinated effort to understand their optimal processing conditions and final properties [29,30].…”

mentioning

confidence: 99%

Fatigue Behavior of As-Built L-PBF A357.0 Parts

Bassoli

Denti

Comin

et al. 2018

Metals

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Laser-based powder bed fusion (L-PBF) is nowadays the preeminent additive manufacturing (AM) technique to produce metal parts. Nonetheless, relatively few metal powders are currently available for industrial L-PBF, especially if aluminum-based feedstocks are involved. In order to fill the existing gap, A357.0 (also known as A357 or A13570) powders are here processed by L-PBF and, for the first time, the fatigue behavior is investigated in the as-built state to verify the net-shaping potentiality of AM. Both the low-cycle and high-cycle fatigue areas are analyzed to draw the complete Wohler diagram. The infinite lifetime limit is set to 2 × 10 6 stress cycles and the staircase method is applied to calculate a mean fatigue strength of 60 MPa. This value is slightly lower but still comparable to the published data for AlSi10Mg parts manufactured by L-PBF, even if the A357.0 samples considered here have not received any post-processing treatment.Keywords: additive manufacturing; laser-based powder bed fusion; aluminum; fatigue strength present in AM parts, which may impact the mechanical behavior of finished constructs [3].Originally developed for rapid prototyping, AM is now growing very rapidly in terms of production numbers and economic importance. According to recent estimations, the sale of AM products and services is expected to grow from US $5.2 billion in 2015 to over US $26.5 billion by 2021. If metal AM is considered, according to statistics, 1768 AM systems were sold in 2017, compared to 983 systems in 2016, thus scoring an impressive increase of nearly 80% [4].Standard ISO/ASTM 52900-15 [5], which defines general principles and terminology for AM, groups AM techniques into seven categories, all of which are compatible with polymer feedstocks. However, only three of these processes, including powder bed fusion, direct energy deposition, and sheet lamination, also apply to metals. Among them, powder bed fusion (PBF) is emerging as the most promising one, on account of its flexibility in terms of part design and feedstock availability.In PBF, thermal energy is used to selectively consolidate specific areas of the powder bed, which is a relatively thin layer of fresh powder (typically below 100 µm) evenly distributed on top of the previously consolidated powder layers. The heat input may be supplied by an electron beam, in electron beam melting (EBM), or by a laser beam, in laser-based powder bed fusion (L-PBF). In the latter case, consolidation may rely upon sintering (direct laser sintering, DLS, also known as selective laser sintering, SLS) or complete melting-solidification mechanisms (selective laser melting, SLM) [6]. As a rule, the energy conveyed to the powder bed is enough to affect not only the new powder layer, but also the material underneath, so as to provide interlayer bonding [7].At present, in spite of the increasingly widespread diffusion of AM in the industry, there is still a lack of understanding of the mechanical behavior of materials processed by L-PBF, especially aluminum and its alloys...

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Improving the Defect Tolerance and Fatigue Strength of AM AlSi10Mg

2023

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Additively manufactured structures reveal a poor surface quality and a high number of process‐induced defects in the surface‐near area, leading to a significant reduction of the fatigue strength. As laser‐based powder bed fusion (PBF‐LB) processes are used to produce topologically optimized lightweight structures with complex geometries, which cannot be fully machined, the influence of the process‐induced surface on the fatigue behavior needs to be analyzed. For this, also the interrelation of the surface‐induced notch effects with the surrounding material volume must be considered. As thermal treatments can also be applied to filigree components with complex geometries, in the presented work the influence of different heat treatments, i.e., stress relief annealing (SR) and artificial aging (T6), on the material properties, especially the defect tolerance, of AlSi10Mg manufactured via PBF‐LB is analyzed. Both heat treatments lead to a dissolution of the cellular Si‐rich network, resulting in decreased hardness and tensile strength, but higher fatigue strength. The increased fatigue strength results from a reduction of the process‐induced residual stresses, but mainly a strongly improved defect tolerance. Consequently, to evaluate the fatigue strength of additively manufactured materials, besides the materials strength and the process‐induced defects, also the defect tolerance must be considered.

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Fatigue of AlSi10Mg specimens fabricated by additive manufacturing selective laser melting (AM-SLM)

Cited by 256 publications

References 25 publications

VHCF response of as‐built SLM AlSi10Mg specimens with large loaded volume

VHCF response of as‐built SLM AlSi10Mg specimens with large loaded volume

Fatigue Behavior of As-Built L-PBF A357.0 Parts

Improving the Defect Tolerance and Fatigue Strength of AM AlSi10Mg

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