Very high-cycle fatigue properties and microstructural damage mechanisms of selective laser melted AlSi10Mg alloy

Awd, Mustafa; Siddique, Shafaqat; Johannsen, Jan; Emmelmann, Claus; Walther, Frank

doi:10.1016/j.ijfatigue.2019.02.040

Cited by 54 publications

(60 citation statements)

References 39 publications

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“…Moreover, there is increasing interest on the very high cycle fatigue (VHCF) behavior of AM parts, since in many structural applications the required fatigue life is significantly larger than that assessed through HCF tests. In particular, the VHCF response of AM Ti6Al4V [17,18], AlSi12 [19], and AlSi10Mg [20][21][22] alloys has been recently investigated in the literature. As for the AM AlSi10Mg alloy, the VHCF response up to 10 9 cycles of as-built and stress-relieved Gaussian specimens with horizontal building direction was studied in [20,21], respectively.…”

Section: Introductionmentioning

confidence: 99%

“…As for the AM AlSi10Mg alloy, the VHCF response up to 10 9 cycles of as-built and stress-relieved Gaussian specimens with horizontal building direction was studied in [20,21], respectively. Siddique et al [22] investigated the VHCF response up to 10 8 cycles of AM AlSi10Mg hourglass specimens with a vertical building direction. In particular, in [22], the positive effect of platform heating, which affects the defect morphology and microstructure, was experimentally assessed, and a pore-crack interaction mechanism during crack propagation was shown through X-ray computed tomography.…”

Section: Introductionmentioning

confidence: 99%

“…Siddique et al [22] investigated the VHCF response up to 10 8 cycles of AM AlSi10Mg hourglass specimens with a vertical building direction. In particular, in [22], the positive effect of platform heating, which affects the defect morphology and microstructure, was experimentally assessed, and a pore-crack interaction mechanism during crack propagation was shown through X-ray computed tomography. At present, even though it is well-known that size effects significantly influence the VHCF response of wrought [23] and AM parts [24], no experimental tests have been carried out on AM AlSi10Mg specimens with a large risk volume (i.e., the volume of the material subjected to a stress amplitude larger than 90% of the maximum applied stress [25]) and a vertical building direction.…”

Section: Introductionmentioning

confidence: 99%

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VHCF Response up to 109 Cycles of SLM AlSi10Mg Specimens Built in a Vertical Direction

et al. 2019

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It is well-known that many manufacturing parameters affect the quasi-static and the fatigue response of additive manufacturing (AM) parts. In particular, due to the layer-by-layer production, the load orientation, with respect to the building direction, plays a fundamental role for the fatigue response. This paper investigates the fatigue response up to 10 9 cycles (very high cycle fatigue (VHCF)) of selective laser melting (SLM) AlSi10Mg specimens built in a vertical direction. Ultrasonic tension-compression tests (stress ratio of -1) are carried out on as-built Gaussian specimens with a large loaded volume (2300 mm 3 ). Fracture surfaces are investigated with the scanning electron microscope to analyze the defects originating the VHCF failure. Probabilistic S-N curves are estimated and analyzed. Experimental results confirm that the defect size controls the VHCF response, thus highlighting the importance of testing large risk volumes for a reliable assessment of VHCF behavior. The average value of the VHCF strength is close to that of the hourglass specimen tested in the literature. The variability of the VHCF strength is instead significantly larger, due to the scattered size distribution of the defects located near the specimen surface, which is the most critical region for crack initiation.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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VHCF Response up to 109 Cycles of SLM AlSi10Mg Specimens Built in a Vertical Direction

et al. 2019

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“…According to Table , the VHCF strength of hourglass specimens tested in Awd et al is larger than the VHCF strength of large Gaussian specimens built in horizontal and vertical direction. The difference could be due to the different tested risk volumes (and, accordingly, to a possible size effect) and to the different testing condition (hourglass specimens were machined after the AM process).…”

Section: Alsi10mg: Vhcf Test Resultsmentioning

confidence: 99%

“…and in Shamsaei et al 4 ("Due to the lack of VHCF studies for AM materials, there is a critical need to obtain the fatigue behavior at gigacycles and the influences of design parameters, size/geometry, surface roughness, etc. "), the fatigue response at number of cycles above 10 8 and in the VHCF region should be also carefully investigated to completely characterize the fatigue response of AM parts.…”

Section: Introductionmentioning

confidence: 99%

VHCF response of AM materials: A literature review

Tridello

Paolino

2019

Mat Design & Process Comms

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The present paper is an overview of the recent experimental results on the Very High Cycle Fatigue (VHCF) response of materials produced through additive manufacturing (AM) processes. At present, VHCF tests have been carried out on AlSi12, AlSi10Mg, and Ti6Al4V specimens produced through AM processes (SLM and EBM). The VHCF strength and the main findings provided in the literature are analyzed in the paper, focusing on the main factors that affect the fatigue response. KEYWORDSadditive manufacturing, very high cycle fatigue (VHCF), AlSi12, AlSi10Mg, Ti6Al4V

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Review on Fatigue of Additive Manufactured Metallic Alloys: Microstructure, Performance, Enhancement, and Assessment Methods

Liu,

Yu,

Guo

et al. 2023

Advanced Materials

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Additive manufacturing (AM), which is a process of building objects in a layer‐upon‐layer fashion from designed models, has received unprecedented attention from research and industry because it offers outstanding merits of flexibility, customization, reduced buy‐to‐fly ratio, and cost‐effectiveness. However, the fatigue performance of safety‐critical industrial components fabricated by AM is still far below that obtained from conventional methods. This review discusses the microstructural heterogeneities, randomly dispersed defects, poor surface quality, and complex residual stress generated during the AM process that can negatively impact the fatigue performance of as‐printed parts. The difference in microstructural origin of fatigue failure between conventionally manufactured and printed metals is reviewed with particular attention to the effects of the trans‐scale microstructures on AM fatigue failure mechanisms. Various methods for mitigating the fatigue issue, including pre‐process, inter‐process and post‐process treatments, are illustrated. Empirical, semi‐empirical and microstructure‐sensitive models are presented to predict fatigue strength and lifetime. Summary and outlooks for future development of the fatigue performance of AM materials are provided.This article is protected by copyright. All rights reserved

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Very high-cycle fatigue properties and microstructural damage mechanisms of selective laser melted AlSi10Mg alloy

Cited by 54 publications

References 39 publications

VHCF Response up to 109 Cycles of SLM AlSi10Mg Specimens Built in a Vertical Direction

VHCF Response up to 109 Cycles of SLM AlSi10Mg Specimens Built in a Vertical Direction

VHCF response of AM materials: A literature review

Review on Fatigue of Additive Manufactured Metallic Alloys: Microstructure, Performance, Enhancement, and Assessment Methods

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