journal article·2024-10Open access

Influence of the as-built surface and a T6 heat treatment on the fatigue behavior of additively manufactured AlSi10Mg

Patrick Lehner, Bastian Blinn, Tong Zhu, Ali Al-Zuhairi, Marek Smaga, Roman Teutsch, Tilmann Beck

Abstract

As the fatigue strength of materials manufactured via lase-based powder bed fusion (PBF-LB) is highly influenced by process-induced defects and the “as-built” surface, in this work fatigue tests at specimens made of AlSi10Mg with “as-built” and polished surface condition were conducted. In this context also the defect tolerance of the material, and hence its ability to counteract process-induced notch effects, was analyzed. For this, specimens in a not heat-treated and an artificially aged (T6) condition were tested. For the not heat-treated specimens, a high reduction of the fatigue strength due to the “as-built” surface is observed, while the heat-treated specimens exhibit no influence of the surface condition. Using the √area approach, it is demonstrated that the smaller fatigue strength due to “as-built” surface observed for the not heat-treated condition results from process-related residual tensile stresses, which are removed by T6 heat treatment and polishing, respectively. Moreover, the results show that the “as-built” surface leads to similar stress concentrations than defects in the specimen volume, and thus, polishing had no influence on the fatigue performance after heat treatment. In addition to these findings, an increased fatigue strength after T6 heat treatment was observed, which is caused by an increased defect tolerance.
Source: openalex_inverted_index · Quality: baseline

Research context

OpenAlex topics: Additive Manufacturing Materials and Processes · Additive Manufacturing and 3D Printing Technologies · Welding Techniques and Residual Stresses

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (78)

Show source-provided references
1. Fracture and fatigue in additively manufactured metals10.1016/j.actamat.2021.117240 ↗
2. Additive manufacturing of metallic components – process, structure and properties10.1016/j.pmatsci.2017.10.001 ↗
3. Influence of process-induced microstructure and imperfections on mechanical properties of AlSi12 processed by selective laser melting10.1016/j.jmatprotec.2015.02.023 ↗
4. Density of additively-manufactured, 316L SS parts using laser powder-bed fusion at powers up to 400 W10.1007/s00170-014-5954-9 ↗
5. The influence of processing parameters on the mechanical properties of SLM Parts10.1016/j.proeng.2015.01.510 ↗
6. Fracture resistance of AlSi10Mg fabricated by laser powder bed fusion10.1016/j.actamat.2021.116869 ↗
7. A study of the microstructural evolution during selective laser melting of Ti–6Al–4V10.1016/j.actamat.2010.02.004 ↗
8. Study on the fatigue behaviour of selective laser melted AlSi10Mg alloy10.1016/j.msea.2020.139180 ↗
9. Tuning the hardness of produced parts by adjusting the cooling rate during laser-based powder bed fusion of AlSi10Mg by adapting the process parameters10.3390/met12122000 ↗
10. Factors that affect the properties of additively-manufactured AlSi10Mg: porosity versus microstructure
11. Knowledge of process-structure-property relationships to engineer better heat treatments for laser powder bed fusion additive manufactured Inconel 718
12. Fine-structured aluminium products with controllable texture by selective laser melting of pre-alloyed AlSi10Mg powder10.1016/j.actamat.2012.11.052 ↗
13. Mechanical behavior of additive manufactured, powder-bed laser-fused materials10.1016/j.msea.2015.10.068 ↗
14. Change in microstructure of selectively laser melted AlSi10Mg alloy with heat treatments10.1016/j.msea.2017.08.029 ↗
15. High-cycle-fatigue properties of selective-laser-melted AlSi10Mg with multiple building directions10.1016/j.ijmecsci.2022.107336 ↗
16. Effect of microstructure, residual stresses and building orientation on the fatigue response up to 109 cycles of an SLM AlSi10Mg alloy10.1016/j.ijfatigue.2020.105659 ↗
17. Selective laser melting of AlSi10Mg: Influence of post-processing on the microstructural and tensile properties development10.1016/j.matdes.2016.05.066 ↗
18. Influence of additive multilayer feature on thermodynamics, stress and microstructure development during laser 3D printing of aluminum-based material10.1016/j.scib.2017.05.007 ↗
19. Investigation of crystal growth mechanism during selective laser melting and mechanical property characterization of 316L stainless steel parts10.1016/j.matdes.2016.03.111 ↗
20. Microstructure, precipitates and hardness of selectively laser melted AlSi10Mg alloy before and after heat treatment10.1016/j.matchar.2018.04.022 ↗
21. Nanoscale periodic gradients generated by laser powder bed fusion of an AlSi10Mg alloy10.1016/j.matdes.2020.109264 ↗
22. Changes in the microstructure and mechanical properties of additively manufactured AlSi10Mg alloy after exposure to elevated temperatures10.1016/j.matchar.2018.01.028 ↗
23. Reducing porosity in AlSi10Mg parts processed by selective laser melting
24. Fatigue of AlSi10Mg specimens fabricated by additive manufacturing selective laser melting (AM-SLM)10.1016/j.msea.2017.08.027 ↗
25. Influence of heat treatment on the high-cycle fatigue properties and fatigue damage mechanism of selective laser melted AlSi10Mg alloy10.1016/j.msea.2021.141486 ↗
26. Zhao, L.; Santos Macías, J. G.; Ding, L.; Idrissi, H.; Simar, A.: Damage mechanisms in selective laser melted AlSi10Mg under as built and different post-treatment conditions. Mater Sci Eng A 764. 2019: S. 138210.10.1016/j.msea.2019.138210 ↗
27. An overview of residual stresses in metal powder bed fusion
28. Additive manufactured AlSi10Mg samples using Selective Laser Melting (SLM): Microstructure, high cycle fatigue, and fracture behavior10.1016/j.matdes.2011.07.067 ↗
29. Beretta, S.; Gargourimotlagh, M.; Foletti, S.; Du Plessis, A.; Riccio, M.: Fatigue strength assessment of “as built” AlSi10Mg manufactured by SLM with different build orientations. Int J Fatig 139. 2020: S. 105737.10.1016/j.ijfatigue.2020.105737 ↗
30. Zhao, L.; Santos Macías, J. G.; Dolimont, A.; Simar, A.; Rivière-Lorphèvre, E.: Comparison of residual stresses obtained by the crack compliance method for parts produced by different metal additive manufacturing techniques and after friction stir processing. Addi Manuf 36. 2020: S. 101499.10.1016/j.addma.2020.101499 ↗
31. Influence of the annealing and defects on the VHCF behavior of an SLM AlSi10Mg alloy10.1111/ffe.13123 ↗
32. Influence of sub-cell structure on the mechanical properties of AlSi10Mg manufactured by laser powder bed fusion10.1016/j.msea.2020.138976 ↗
33. Fatigue crack growth behavior of a selective laser melted AlSi10Mg10.1016/j.engfracmech.2019.106564 ↗
34. Improving the fatigue behaviour of a selectively laser melted aluminium alloy: Influence of heat treatment and surface quality10.1016/j.matdes.2016.05.041 ↗
35. On the Precipitation Hardening of Selective Laser Melted AlSi10Mg10.1007/s11661-015-2980-7 ↗
36. Investigation of the sensitivity of the fatigue resistance to defect position in aluminium alloys obtained by Selective laser melting using artificial defects10.1016/j.ijfatigue.2020.105505 ↗
37. Domfang Ngnekou, J. N.; Nadot, Y.; Henaff, G.; Nicolai, J.; Ridosz, L.: Effect of As-Built and Ground Surfaces on the Fatigue Properties of AlSi10Mg Alloy Produced by Additive Manufacturing. 2021.10.3390/met11091432 ↗
38. Fatigue properties of AlSi10Mg produced by Additive Layer Manufacturing10.1016/j.ijfatigue.2018.09.029 ↗
39. On the fatigue strength enhancement of additive manufactured AlSi10Mg parts by mechanical and thermal post-processing10.1016/j.matdes.2018.02.055 ↗
40. Effect of heat treatments on fatigue property of selective laser melting AlSi10Mg10.1016/j.ijfatigue.2018.07.016 ↗
41. Linking microstructure and processing defects to mechanical properties of selectively laser melted AlSi10Mg alloy10.1016/j.tafmec.2018.09.011 ↗
42. Defect Analysis for Additively Manufactured Materials in Fatigue from the Viewpoint of Quality Control and Statistics of Extremes10.1016/j.prostr.2019.12.014 ↗
43. Fatigue properties of AlSi10Mg obtained by additive manufacturing: Defect-based modelling and prediction of fatigue strength10.1016/j.engfracmech.2017.11.002 ↗
44. Influence of microstructural defects and the surface topography on the fatigue behavior of “additively-subtractively” manufactured specimens made of AISI 316L10.1002/mawe.202000266 ↗
45. Influence of defects, surface roughness and HIP on the fatigue strength of Ti-6Al-4V manufactured by additive manufacturing10.1016/j.ijfatigue.2018.07.020 ↗
46. Effect of Post Treatment on the Microstructure, Surface Roughness and Residual Stress Regarding the Fatigue Strength of Selectively Laser Melted AlSi10Mg Structures10.3390/jmmp3040089 ↗
47. Murakami · 2002
48. Effects of building orientation and heat treatment on fatigue behavior of selective laser melted 17–4 PH stainless steel10.1016/j.ijfatigue.2016.03.014 ↗
49. Crack initiation behavior and fatigue performance up to very-high-cycle regime of AlSi10Mg fabricated by selective laser melting with two powder sizes10.1016/j.ijfatigue.2020.106013 ↗
50. Surface quality and fatigue behavior of L-PBF AlSi10Mg in as-built condition10.1016/j.prostr.2021.12.020 ↗
51. Additive manufacturing of fatigue resistant materials: Challenges and opportunities10.1016/j.ijfatigue.2017.01.001 ↗
52. A comparison of fatigue strength sensitivity to defects for materials manufactured by AM or traditional processes10.1016/j.ijfatigue.2016.06.020 ↗
53. Defects as a root cause of fatigue weakening of additively manufactured AlSi10Mg components10.1016/j.tafmec.2020.102611 ↗
54. Effects of Defects in Laser Additive Manufactured Ti-6Al-4V on Fatigue Properties10.1016/j.phpro.2014.08.120 ↗
55. Improvement of fatigue resistance and ductility of TiAl6V4 processed by selective laser melting10.1016/j.jmatprotec.2015.01.025 ↗
56. Fatigue performance of additive manufactured metallic parts10.1108/13552541311302932 ↗
57. Influence of as-built surfaces on the fatigue behavior of AlSi10Mg parts obtained by laser powder bed fusion10.1016/j.prostr.2020.02.035 ↗
58. On the fatigue properties of metals manufactured by selective laser melting – The role of ductility10.1557/jmr.2014.157 ↗
59. Determination of the influence of a stress-relief heat treatment and additively manufactured surface on the fatigue behavior of selectively laser melted AISI 316L by using efficient short-time procedures10.1016/j.ijfatigue.2019.105301 ↗
60. Improving the Defect Tolerance and Fatigue Strength of AM AlSi10Mg10.1002/adem.202201855 ↗
61. DIN EN ISO 25178-2:2012-09, Geometrische Produktspezifikation (GPS)_- Oberflächenbeschaffenheit: Flächenhaft_- Teil_2: Begriffe und Oberflächen-Kenngrößen (ISO_25178-2:2012); Deutsche Fassung EN_ISO_25178-2:2012: Beuth Verlag GmbH, Berlin.
62. DIN EN ISO 6892-1:2020-06, Metallische Werkstoffe_- Zugversuch_- Teil_1: Prüfverfahren bei Raumtemperatur (ISO_6892-1:2019); Deutsche Fassung EN_ISO_6892-1:2019: Beuth Verlag GmbH, Berlin.
63. PhyBaLCHT – Influence of indentation force on the results of cyclic hardness tests and investigations of comparability to uniaxial fatigue loading10.1016/j.ijfatigue.2018.09.025 ↗
64. Cyclic hardness test PHYBALCHT – Short-time procedure to evaluate fatigue properties of metallic materials10.1016/j.ijfatigue.2014.01.009 ↗
65. Görzen, D.; Schwich, H.; Blinn, B.; Song, W.; Krupp, U.; Bleck, W.; Beck, T.: Influence of Cu precipitates and C content on the defect tolerance of steels. Int J Fatig 144. 2021: S. 106042.10.1016/j.ijfatigue.2020.106042 ↗
66. Proposal of method for estimation stress intensity factor range on small crack for light metals
67. Qualification of uniform fatigue damage tolerance law for additively manufactured and cast Al-Si alloys10.1016/j.prostr.2022.12.040 ↗
68. High-frequency cyclic testing of welded aluminium alloy joints in the region of very high cycle fatigue (VHCF)10.1016/j.ijfatigue.2012.10.012 ↗
69. Oberreiter, M.; Horvath, M.; Stoschka, M.; Fladischer, S.: Effect of Surface Finishing State on Fatigue Strength of Cast Aluminium and Steel Alloys. Materials (Basel, Switzerland) 16 (13). 2023.10.3390/ma16134755 ↗
70. About the fatigue crack propagation threshold of metals as a design criterion – a review10.1016/j.engfracmech.2015.12.002 ↗
71. Near-threshold fatigue crack growth behavior in metals10.1016/0001-6160(83)90155-4 ↗
72. Borges, M. F.; Antunes, F. V.; Prates, P. A.; Branco, R.; Vojtek, T.: Effect of Young’s modulus on fatigue crack growth. Int J Fatig 132. 2020: S. 105375.10.1016/j.ijfatigue.2019.105375 ↗
73. Fatigue crack growth thresholds—the influence of Young's modulus and fracture surface roughness10.1016/S0142-1123(98)00034-6 ↗
74. On the Simulation Scalability of Predicting Residual Stress and Distortion in Selective Laser Melting10.1115/1.4038893 ↗
75. The effect of surface and subsurface condition on the fatigue life of Ti–25V–15Cr–2Al–0.2C %wt alloy10.1016/j.cirp.2016.04.074 ↗
76. Study on improvement of surface roughness and induced residual stress for additively manufactured metal parts by abrasive flow machining10.1016/j.procir.2018.05.046 ↗
77. Roveda, I.; Serrano-Munoz, I.; Haubrich, J.; Requena, G.; Madia, M.: Influence of post-process heat treatments on the fatigue crack propagation behaviour of a PBF-LB/M AlSi10Mg alloy. Int J Fatig 175. 2023: S. 107808.10.1016/j.ijfatigue.2023.107808 ↗
78. The cyclic R-curve – determination, problems, limitations and application10.1016/j.engfracmech.2017.09.032 ↗