Review on the correlation between microstructure and mechanical performance for laser powder bed fusion AlSi10Mg

Zhao, Lv; Song, Lubin; Macías, Juan Guillermo Santos; Zhu, Yaxin; Huang, Minsheng; Simar, Aude; Li, Zhenhuan

doi:10.1016/j.addma.2022.102914

Cited by 80 publications

(80 citation statements)

References 230 publications

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“…Laser-based powder bed fusion (L-PBF) technology offers several advantages over conventional processing, providing unique opportunities for component design to enhance mechanical performance and reduce the environmental impact by producing strengthoptimized structures [1,2]. Heat sinks, engine and gas turbine parts, and aerodynamic components are a few of the possible high-value-added parts manufactured by L-PBF technology [3,4].…”

Section: Introductionmentioning

confidence: 99%

“…The as-built (AB) L-PBF AlSi10Mg alloy has an ultrafine microstructure consisting of supersatured α-Al cells and a Si-rich eutectic phase, which solidifies within a melt pool (MP) structure according to the adopted layer-by-layer deposition and scanning strategy [2,4]. The strengthening mechanisms derived from this peculiar microstructure promote high hardness and tensile strength values at the expense of ductility [8].…”

Section: Introductionmentioning

confidence: 99%

“…Instead, an optimal balance between the static mechanical properties is essential for improving fatigue performance in the structural component. High yield strength and ductility improve fatigue strength; they mitigate, in fact, the adverse effects of the local stress intensification factor at the defect tip and make the component less susceptible to fatigue crack initiation [2,10]. For this reason, several authors focused on optimizing postprocessing heat treatments to overcome the limitations of the AB alloy, thus increasing fatigue strength [10][11][12][13][14][15][16][17][18].…”

Section: Introductionmentioning

confidence: 99%

“…Even though the fatigue properties of the L-PBF AlSi10Mg parts have been the subject of an increasing investigation inherent to room-temperature fatigue properties, the effects of the high temperatures on the cyclic mechanical response have been quite completely neglected [2]. The progressive loss of the strengthening mechanisms above 200 • C due to the low thermal stability of the L-PBF AlSi10Mg alloy can limit the use in producing components directly or indirectly exposed to high temperatures.…”

Section: Introductionmentioning

confidence: 99%

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Room- and High-Temperature Fatigue Strength of the T5 and Rapid T6 Heat-Treated AlSi10Mg Alloy Produced by Laser-Based Powder Bed Fusion

Zanni

Ceschini

Morri

et al. 2023

Metals

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The AlSi10Mg alloy produced by laser-based powder bed fusion (L-PBF) is widely used to produce high-value-added structural parts subjected to cyclic mechanical loads at high temperatures. The paper aims to widen the knowledge of the room- and high-temperature (200 °C) fatigue behavior of the L-PBF AlSi10Mg alloy by analyzing the fully reversed rotating bending test results on mechanically polished specimens. Two heat-treated conditions are analyzed: T5 (direct artificial aging: 4 h at 160 °C) and novel T6R (rapid solution: 10 min at 510 °C, artificial aging: 6 h at 160 °C). The study highlights that (i) the T6R alloy is characterized by higher fatigue strength at room (108 MPa) and high temperatures (92 MPa) than the T5 alloy (92 and 78 MPa, respectively); (ii) thermal exposure at 200 °C up to 17 h does not introduce macroscopical microstructural variation; (iii) fracture surfaces of the room- and high-temperature-tested specimens show comparable crack initiation, mostly from sub-superficial gas and keyhole pores, and failure propagation mechanisms. In conclusion, the L-PBF AlSi10Mg alloy offers good cyclic mechanical performances under various operating conditions, especially for the T6R alloy, and could be considered for structural components operating at temperatures up to 200 °C.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Room- and High-Temperature Fatigue Strength of the T5 and Rapid T6 Heat-Treated AlSi10Mg Alloy Produced by Laser-Based Powder Bed Fusion

Zanni

Ceschini

Morri

et al. 2023

Metals

View full text Add to dashboard Cite

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“…Furthermore, Al alloy parts fabricated by PBF-based AM tend to have superior characteristics, such as high specific strength, high fatigue resistance, and a high degree of physical flexibility. Therefore, they have been widely adopted in industrial fields, such as manufacturing automobiles, motorcycles, airplanes, and spacecraft [ 2 , 3 , 4 , 5 , 6 , 7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 , 15 , 16 , 17 , 18 ]. Al alloys with fine equiaxed grain microstructures exhibit excellent characteristics with respect to the aforesaid applications; therefore, inoculants are introduced as heterogeneous nucleation sites for further microstructure refinement [ 5 , 6 , 7 , 8 , 9 , 19 , 20 , 21 ].…”

Section: Introductionmentioning

confidence: 99%

Effect of Rapid Heating and Cooling Conditions on Microstructure Formation in Powder Bed Fusion of Al-Si Hypoeutectic Alloy: A Phase-Field Study

2022

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Al alloy parts fabricated by powder bed fusion (PBF) have attracted much attention because of the degrees of freedom in both shapes and mechanical properties. We previously reported that the Si regions in Al-Si alloy that remain after the rapid remelting process in PBF act as intrinsic heterogeneous nucleation sites during the subsequent resolidification. This suggests that the Si particles are crucial for a novel grain refinement strategy. To provide guidelines for grain refinement, the effects of solidification, remelting, and resolidification conditions on microstructures were investigated by multiphase-field simulation. We revealed that the resolidification microstructure is determined by the size and number of Si regions in the initial solidification microstructures and by the threshold size for the nucleation site, depending on the remelting and resolidification conditions. Furthermore, the most refined microstructure with the average grain size of 4.8 µm is predicted to be formed under conditions with a large temperature gradient of Gsol = 106 K/m in the initial solidification, a high heating rate of HR = 105 K/s in the remelting process, and a fast solidification rate of Rresol = 10−1 m/s in the resolidification process. Each of these conditions is necessary to be considered to control the microstructures of Al-Si alloys fabricated via PBF.

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High‐Temperature Creep Behavior of Selective‐Laser‐Melting‐Fabricated Lattice Structures Inspired from Euplectella Aspergillum

Sharma,

Hiremath

2023

Adv Eng Mater

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The study uses the lattice‐like arrangement of Euplectella aspergillum to derive bionic grid‐stiffened structures in the form of thin tubes. The bionic tubes are 3D printed with AlSi10Mg alloy using a selective laser melting (SLM) process. High‐temperature creep behavior at 250 ◦C and stress (0.3‐0.7) times yield strength of the tubes is studied under uni‐axial constant compressive load. The effect of the stress level, temperature, and tube design on the creep performance and deformation behavior is studied. The creep performance of bio‐inspired tubes is compared with honeycomb lattice tubes. Results showed the dependence of creep life and creep rate on the design of the bionic tubes. E. aspergillum based thin tubes showed higher creep life and lower creep rate as compared to honeycomb based tubes at all stress levels. Also, the creep curves of lattice structures based thin tubes are different than the solid material, especially in the primary and tertiary regions. The fractography analysis showed higher creep life in E. aspergillum inspired thin tubes is due to the improvement in ductility at high temperature. The stress exponent value in the Mukherjee‐Bird‐Dorn equation shows that the mechanism of creep is diffusion. Results here showed that bio‐inspiration and additive manufacturing provide an opportunity to design and fabricate advanced iso‐grids structures. Such lattice‐based thin tubes can be used to form self‐stiffened structures in the hot section of aircraft and space vehicles where low weight, stiffness, strength, and damage tolerance are important.This article is protected by copyright. All rights reserved.

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Review on the correlation between microstructure and mechanical performance for laser powder bed fusion AlSi10Mg

Cited by 80 publications

References 230 publications

Room- and High-Temperature Fatigue Strength of the T5 and Rapid T6 Heat-Treated AlSi10Mg Alloy Produced by Laser-Based Powder Bed Fusion

Room- and High-Temperature Fatigue Strength of the T5 and Rapid T6 Heat-Treated AlSi10Mg Alloy Produced by Laser-Based Powder Bed Fusion

Effect of Rapid Heating and Cooling Conditions on Microstructure Formation in Powder Bed Fusion of Al-Si Hypoeutectic Alloy: A Phase-Field Study

High‐Temperature Creep Behavior of Selective‐Laser‐Melting‐Fabricated Lattice Structures Inspired from Euplectella Aspergillum

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