Laser welding of AlSi10Mg aluminium-based alloy produced by Selective Laser Melting (SLM)

Mäkikangas, Jarmo; Rautio, Timo; Mustakangas, Aappo; Mäntyjärvi, Kari

doi:10.1016/j.promfg.2019.08.013

Cited by 30 publications

(21 citation statements)

References 7 publications

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“…However, the size of the components that can be produced with LPBF is not only limited technologically by the volume of the construction chamber but also by economic factors. [ 3–5 ] For example, the high costs of powder and low build rates often make additively manufactured (AM) components more expensive than those produced by conventional manufacturing methods. [ 4 ] Size limitations can be overcome to a degree by joining two AM components subsequent to their production, or by hybrid construction of components made by AM with conventionally manufactured parts.…”

Section: Introductionmentioning

confidence: 99%

“…[ 4 ] Size limitations can be overcome to a degree by joining two AM components subsequent to their production, or by hybrid construction of components made by AM with conventionally manufactured parts. [ 5,6 ] By combining AM and conventionally manufactured components or structures, AM components can be used specifically in a manner where a high degree of complexity or functionality is required for the application, resulting in cost savings. Therefore, one way to extend the application range of AM as a new industrial manufacturing technology is hybrid design in combination with a suitable joining technology.…”

Section: Introductionmentioning

confidence: 99%

“…Nevertheless, relatively few investigations have been conducted and published on the welding behavior of AM components, and, in particular, with respect to Al alloys. [ 3–8 ]…”

Section: Introductionmentioning

confidence: 99%

“…It is known that pronounced porosity typically occurs after welding of Al–LPBF material using the keyhole mode. [ 3–5 ] This porosity can be mitigated by reducing the welding speed [ 3,4 ] or by using a multispot welding technique. [ 7 ] It should be noted that pore‐free welds can only be produced by changing the welding mode to heat‐conduction welding.…”

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Investigation of Pore Reduction in Hybrid Joints of Conventionally and Additively Manufactured AlSi10Mg Using Electron Beam Welding

Michler

Hollmann

Zenker³

et al. 2021

Adv Eng Mater

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Laser powder bed fusion (LPBF) is particularly well suited for the production of geometrically complex functional metal components. However, the size of the components that can be produced is limited technologically by the volume of the construction chamber, and economically by the low build‐up rates. With the provision of a reliable welding technology, size limitations can potentially be overcome to a degree by joining two additively manufactured (AM) components or by hybrid construction of components. Therefore, this study investigates the production of hybrid joints from additively and conventionally manufactured AlSi10Mg material by electron beam welding (EBW). It is known that EBW of LPBF‐processed aluminum alloys in the keyhole welding mode results in the distinctive formation of pores in the weld seams. To avoid this, two different joining strategies are pursued, namely, beam offset and multispot welding methods. It is thus determined that an adequate weld seam quality can only be achieved by means of a three‐spot welding process with adapted EB parameters. Accordingly, the investigations prove the applicability of the EB keyhole welding mode in EBW for the production of low‐porosity LPBF mixed joints.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

“…Nevertheless, relatively few investigations have been conducted and published on the welding behavior of AM components, and, in particular, with respect to Al alloys. [ 3–8 ]…”

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Investigation of Pore Reduction in Hybrid Joints of Conventionally and Additively Manufactured AlSi10Mg Using Electron Beam Welding

Michler

Hollmann

Zenker³

et al. 2021

Adv Eng Mater

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show abstract

“…Laser welding can be a viable option for the welding of parts with complex geometries. While Alalloys have overall good weldability with lasers despite their high optical reflectivity [31], the weldability of LPBF produced Al-alloys can be difficult due to very large pore formation observed with these materials [32]. Solid state welding processes such as friction stir welding may be another option, but the complexity of the LPBF parts may require complex weld paths not easily applicable to such processes due to the used tools and applied forces.…”

mentioning

confidence: 99%

Laser Powder Bed Fusion of a Topology Optimized and Surface Textured Rudder Bulb with Lightweight and Drag-Reducing Design

Scarpellini

Finazzi

Schito

et al. 2021

JMSE

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This work demonstrates the advantages of using laser powder bed fusion for producing a rudder bulb of a moth class sailing racing boat via laser powder bed fusion (LPBF). The component was designed to reduce weight using an AlSi7Mg0.6 alloy and incorporated a biomimetic surface texture for drag reduction. For the topological optimization, the component was loaded structurally due to foil wing’s lift action as well as from the environment due to hydrodynamic resistance. The aim was to minimize core mass while preserving stiffness and the second to benefit from drag reduction capability in terms of passive surface behavior. The external surface texture is inspired by scales of the European sea bass. Both these features were embedded to the component and produced by LPBF in a single run, with the required resolution. Drag reduction was estimated in the order of for free stream velocity of . The production of the final part resulted in limited geometrical error with respect to scales 3D model, with the desired mechanical properties. A reduction in weight of approximately with respect to original full solid model from 452 to 190 g was achieved thanks to core topology optimization. Sandblasting was adopted as finishing technique since it was able to improve surface quality while preserving fish scale geometries. The feasibility of producing the biomimetic surfaces and the weight reduction were validated with the produced full-sized component.

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Fatigue Strength Assessment of Laser Beam Welded Joints Made of AA7075 and Magnetic Pulse Welded Joints Made of AA7075 and 3D‐Printed AlSi10Mg

et al. 2023

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The use of 7000 aluminum alloys has an important role in future lightweight structures in the field of mobility due to the low density and high strength. However, these alloys can only be fusion welded to a limited extent because welding defects can rarely be prevented. For this reason, investigations are carried out to identify the most suitable welding parameters for two processes: laser beam and magnetic pulse welding. Herein, laser beam welding is successfully used to manufacture a roll‐formed and longitudinally welded pipe made of AA7075 and joined by magnetic pulse welding with a 3D‐printed lug‐tube made of AlSi10Mg. The fatigue strength of these pipe joints and of laser beam welded butt joint specimens is determined using load‐controlled fatigue tests. For the characterization of the specimens, cross sections are prepared and examined metallographically, which reflect the local weld seam geometry in the joining area. A fatigue assessment is made using linear‐elastic approaches. The reference radius concept is applied to map the influence of geometric notches on the fatigue strength, assuming linear‐elastic stress–strain behavior. It is shown that the recommended notch stress fatigue class FAT 178 (von Mises stress) can be applied for a safe and reliable fatigue assessment.

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Laser welding of AlSi10Mg aluminium-based alloy produced by Selective Laser Melting (SLM)

Cited by 30 publications

References 7 publications

Investigation of Pore Reduction in Hybrid Joints of Conventionally and Additively Manufactured AlSi10Mg Using Electron Beam Welding

Investigation of Pore Reduction in Hybrid Joints of Conventionally and Additively Manufactured AlSi10Mg Using Electron Beam Welding

Laser Powder Bed Fusion of a Topology Optimized and Surface Textured Rudder Bulb with Lightweight and Drag-Reducing Design

Fatigue Strength Assessment of Laser Beam Welded Joints Made of AA7075 and Magnetic Pulse Welded Joints Made of AA7075 and 3D‐Printed AlSi10Mg

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