Influence of printing parameters on structures, mechanical properties and surface characterization of aluminium alloy manufactured using selective laser melting

Subbiah, Rajkumar; Bensingh, Joseph; Kader, Abdul; Nayak, Sanjay K.

doi:10.1007/s00170-020-04929-3

Cited by 23 publications

(7 citation statements)

References 25 publications

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“…These results demonstrate that manipulations with 3D-printing orientation and relatively simple and commonly applied mechanical methods of surface treatment give wide range of opportunities for the fine tuning of mechanical response in structural elements of aerospace constructions to purposefully create high demanding parts by design. The variation in the mechanical response of SLM 3D-printed articles at different printing orientations has been widely reported elsewhere [11,12]. Even for nominally identical printing parameters, the variation of local thermal history takes place due to the difference in the cooling conditions depending on the geometry of the printed part, the position of a given volume of interest inside the piece, the design and position of support, and many other aspects.…”

Section: Tensile Test Of 3d-printed Rs-333 Alloy: the Influence Of Surface Qualitymentioning

confidence: 91%

“…These disparate factors interact in a complex manner and lead to the emergence of various hierarchical microstructures with specific characteristics, e.g., arrangement and size of grains, grain boundaries, pores, and reinforcing phase particles. Numerous studies have been reported of the correlation between the fabrication parameters (laser wavelength and power, scanning rate and path width and overlap, growth direction with respect to the sample shape, design of supports, and many others), on the one hand, and internal structure and mechanical and functional properties for many metallic materials [7][8][9][10], specifically for Al alloys [11][12][13], on the other. Elongated columnar crystallites and equiaxed grains appear to be the pre-dominant structural elements in 3Dprinted metals at the dimensional level of 10-300 µm [14].…”

Section: Introductionmentioning

confidence: 99%

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On the Grain Microstructure–Mechanical Properties Relationships in Aluminium Alloy Parts Fabricated by Laser Powder Bed Fusion

Somov

Statnik

Malakhova

et al. 2021

Metals

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Recent years witnessed progressive broadening of the practical use of 3D-printed aluminium alloy parts, in particular for specific aerospace applications where weight saving is of great importance. Selective laser melting (SLM) is an intrinsically multi-parametric fabrication technology that offers multiple means of controlling mechanical properties (elastic moduli, yield strength, and ductility) through the control over grains size, shape, and orientation. Targeted control over mechanical properties is achieved through the tuning of 3D-printing parameters and may even obviate the need of heat treatment or mechanical post-processing. Systematic studies of grain structure for different printing orientations with the help of EBSD techniques in combination with mechanical testing at different dimensional levels are the necessary first steps to implement this agenda. Samples of 3D-printable Al-Mg-Si RS-333 alloy were fabricated in three orientations with respect to the principal build direction and the fast laser beam scanning direction. Sample structure and proper-ties were investigated using a number of techniques, including EBSD, in situ SEM tensile testing, roughness measurements, and nanoindentation. The as-printed samples were found to display strong variation in Young’s modulus values from nanoindentation (from 43 to 66 GPa) and tensile tests (from 54 to 75 GPa), yield stress and ultimate tensile strength (100–195 and 130–220 MPa) in different printing orientations, and almost constant hardness of about 0.8 GPa. A further preliminary study was conducted to assess the effect of surface finishing on the mechanical performance. Surface polishing was seen to reduce Young’s modulus and yield strength but improves ductility, whereas the influence of sandblasting was found to be more controversial. The experimental results are discussed in connection with the grain morphology and orientation.

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Section: Tensile Test Of 3d-printed Rs-333 Alloy: the Influence Of Surface Qualitymentioning

confidence: 91%

Section: Introductionmentioning

confidence: 99%

On the Grain Microstructure–Mechanical Properties Relationships in Aluminium Alloy Parts Fabricated by Laser Powder Bed Fusion

Somov

Statnik

Malakhova

et al. 2021

Metals

View full text Add to dashboard Cite

show abstract

“…The elongation was mainly due to the ductile nature of Aluminium which will be evident during the action of external loads [39]. Even though the presence of SiC particles will restrict the elongation movements, SC samples shows 27.1% higher elongating when compared to the AM samples.…”

Section: Tensile Testmentioning

confidence: 98%

Comparative Study on Morphological, Physical and Mechanical Characteristics of L-PBF Based AlSi10Mg Parts with Conventional Stir Casted Al-10 %SiC Composites

Kumar¹,

Mohan²,

Robinson³

et al. 2021

Silicon

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Stir casting plays a major role in production of Al-SiC10% composites for aero space and automobile applications. However, obtaining the composites with homogenous distribution of the SiC particles, low porosity and without clustering of reinforcement particles were still a major problem faced by the research community. These kinds of casting defects were overcome by the Additive Manufacturing (AM) technology. In this research, AlSi10Mg parts were manufactured by Laser-Powder Bed Fusion (LPBF) method, one of the AM techniques. The mechanical and morphological characteristics of AM samples were compared with the Stir Casted (SC) samples. The in uence of print orientation on the mechanical properties was also evaluated. It was found that the AM samples printed along the XY directions shows 26.5% and 8.2%higher fracture toughness and shear strength than AM samples printed along the Z directions. Both AM and SC samples were analyzed for the porosity% using the Optical Microscope (OM).The result shows that the AM sample shows reduced porosity of 1.4%. Mechanical testing such as tensile test, hardness test, fracture toughness test and double shear stress were carried out. The results obtained from the tensile test AM samples show 14.6% higher tensile strength than the SC samples, from the hardness test AM samples show 18.6% higher hardness strength than the SC samples, from the fracture toughness test AM samples show 33.4% higher fracture toughness strength than the SC samples and from the double shear stress test prove that the AM samples show 24.6% higher shear stress than the SC samples. The outcome of this research, it was proved that additive manufactured AlSi10Mgsample shows enhanced mechanical and morphological properties when compared with the conventional stir casting process.

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“…[8]-[29] Rectangular cross-section samples machined on all sides [3], [30]- [35] Flat cross-section samples cut out of a plate or thin-walled profile [36]- [39] Net shape rectangular cross-section samples that were sandblasted [40] Net shape cylindrical [6], [41]- [43] Mass-produced net shape rectangular samples [44] Understanding the influence of the sample cross-section size on the measured strength is crucial to be able to compare the values of strength reported using different sample geometries. In this article we complement our previous results from [5] with additional study of material microstructure and make a comparison with the results of [6] in order to gain a deeper understanding on how the measured strength and microstructure of SLM-produced AlSi10Mg are affected by the size of printed cross-section.…”

Section: Machined Cylindrical Samplesmentioning

confidence: 99%

On the Influence of Cross-Section Size on Measured Strength of SLM-Produced AlSi10Mg-Alloy

Vysochinskiy

Akhtar

2022

KEM

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The freedom in choice of geometries in additive manufacturing (AM) favors the use of structures with large surface and small cross-section such as lattice structures and thin-walled hollow profiles. On the other hand, the practices of strength testing of metals require a certain bulk of the material to be printed to be able to produce a sample and test material properties. The size of the sample cross section might influence the strength and up to 30% decrease in strength for small struts was reported in the literature. Understanding the influence of the cross-section size on the strength of SLM-produced metal is crucial to be able to relate the strength determined through tensile testing and the strength of an SLM-produced component with complex geometry. This article deals with effect of cross-section size on the measured strength of the SLM-produced AlSi10Mg-alloy. It is demonstrated how the decrease in strength can be explained by the difference between measured and actual cross-section area induced by surface roughness rather than by the difference in microstructure between the samples of different sizes.

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Influence of printing parameters on structures, mechanical properties and surface characterization of aluminium alloy manufactured using selective laser melting

Cited by 23 publications

References 25 publications

On the Grain Microstructure–Mechanical Properties Relationships in Aluminium Alloy Parts Fabricated by Laser Powder Bed Fusion

On the Grain Microstructure–Mechanical Properties Relationships in Aluminium Alloy Parts Fabricated by Laser Powder Bed Fusion

Comparative Study on Morphological, Physical and Mechanical Characteristics of L-PBF Based AlSi10Mg Parts with Conventional Stir Casted Al-10 %SiC Composites

On the Influence of Cross-Section Size on Measured Strength of SLM-Produced AlSi10Mg-Alloy

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