Developing the Additive Manufacturing Chain of AlSi7Mg with Laser Powder Bed Fusion and Tailored Heat Treatments for Railway Spare Parts
Source abstract
Abstract
Abstract The use of metal additive manufacturing technologies in railways sector can provide increased flexibility in terms of spare part logistics. Combined with lightweight metals such as Al-alloys, the product performance can also be enhanced in terms of weight reduction, vibration and noise control. The railway sector is more likely to exploit large and bulky parts produced by laser powder bed fusion (LPBF), which should have appropriate mechanical properties. Therefore, the whole production chain should be analyzed considering the heat treatment steps suited for a distributed and resource efficient manufacturing scheme. Accordingly, this work analyzes the additive manufacturing of AlSi7Mg alloy by LPBF and its consecutive heat treatment steps. In particular, the impact of LPBF process productivity, heat treatment type and atmosphere composition were considered to analyze the most appropriate route for the needs of the railways applications. The results show that with an appropriate direct aging treatment in air, mechanical characteristics of the alloy could be improved, despite that the high layer thickness used in LPBF could increase process productivity. The absence of a quenching step was found to be favorable for large parts, while the absence of an inert gas such as Ar in the heat treatment did not generate any reduction in the mechanical properties.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Additive Manufacturing Materials and Processes · Additive Manufacturing and 3D Printing Technologies · High Entropy Alloys Studies
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (32)
Show source-provided references
1. H. Fu and S. Kaewunruen, State-of-the-Art Review on Additive Manufacturing Technology in Railway Infrastructure Systems, J. Compos. Sci., 2022 https://doi.org/10.3390/jcs601000710.3390/jcs6010007 ↗
2. S.H. Khajavi, J. Partanen, and J. Holmström, Additive Manufacturing in the Spare Parts Supply Chain, Comput. Ind., 2014, 65, p 50–63. https://doi.org/10.1016/j.compind.2013.07.00810.1016/j.compind.2013.07.008 ↗
3. R. Muvunzi, K. Mpofu, I. Daniyan, and F. Fameso, Analysis of Potential Materials for Local Production of a Rail Car Component Using Additive Manufacturing, Heliyon, 2022, 8, p e09405. https://doi.org/10.1016/j.heliyon.2022.e0940510.1016/j.heliyon.2022.e09405 ↗
4. Z. Wu, S. Wu, W. Qian, H. Zhang, H. Zhu, Q. Chen, Z. Zhang, F. Guo, J. Wang, and P.J. Withers, Structural Integrity Issues of Additively Manufactured Railway Components: Progress and Challenges, Eng. Fail. Anal., 2023, 149, p 107265. https://doi.org/10.1016/j.engfailanal.2023.10726510.1016/j.engfailanal.2023.107265 ↗
5. A.D. Toth, J. Padayachee, T. Mahlatji, and S. Vilakazi, Report on Case Studies of Additive Manufacturing in the South African Railway Industry, Sci. Afr., 2022 https://doi.org/10.1016/j.sciaf.2022.e0121910.1016/j.sciaf.2022.e01219 ↗
6. A. Killen, L. Fu, S. Coxon, R. Napper, Exploring the use of additive manufacturing in providing an alternative approach to the design, manufacture and maintenance of interior rail components, in Proceedings of Australasian Transport Research Forum (ATRF 2018), pp 1–16 (2018).
7. P. Kingsland, 3D printing in the railway sector with Deutsche Bahn, Railw. Technol. (2019).
8. E. Maleki, S. Bagherifard, M. Bandini, and M. Guagliano, Surface Post-Treatments for Metal Additive Manufacturing: Progress, Challenges, and Opportunities, Addit. Manuf., 2021, 37, p 101619. https://doi.org/10.1016/j.addma.2020.10161910.1016/j.addma.2020.101619 ↗
9. J. Fiocchi, A. Tuissi, and C.A. Biffi, Heat Treatment of Aluminium Alloys Produced by Laser Powder Bed Fusion: A Review, Mater. Des., 2021 https://doi.org/10.1016/j.matdes.2021.10965110.1016/j.matdes.2021.109651 ↗
10. K.G. Prashanth, S. Scudino, H.J. Klauss, K.B. Surreddi, L. Löber, Z. Wang, A.K. Chaubey, U. Kühn, and J. Eckert, Microstructure and Mechanical Properties of Al-12Si Produced by Selective Laser Melting: Effect of Heat Treatment, Mater. Sci. Eng. A, 2014, 590, p 153–160. https://doi.org/10.1016/j.msea.2013.10.02310.1016/j.msea.2013.10.023 ↗
11. J.L. Bartlett, and X. Li, An Overview of Residual Stresses in Metal Powder Bed Fusion, Addit. Manuf., 2019, 27, p 131–149. https://doi.org/10.1016/j.addma.2019.02.02010.1016/j.addma.2019.02.020 ↗
12. R. Sorci, O. Tassa, A. Colaneri, A. Astri, D. Mirabile, S. Iwnicki, and A.G. Demir, Design of an Innovative Oxide Dispersion Strengthened Al Alloy for Selective Laser Melting to Produce Lighter Components for the Railway Sector, J. Mater. Eng. Perform., 2021, 30, p 5184–5194. https://doi.org/10.1007/s11665-021-05693-510.1007/s11665-021-05693-5 ↗
13. L. Girelli, M. Tocci, L. Montesano, M. Gelfi and A. Pola, Optimization of heat treatment parameters for additive manufacturing and gravity casting AlSi10Mg alloy, in IOP Conference Series: Materials Science and Engineering, vol. 264. https://doi.org/10.1088/1757-899X/264/1/012016 (2017).10.1088/1757-899X/264/1/012016 ↗
14. H. Rao, S. Giet, K. Yang, X. Wu, and C.H.J. Davies, The Influence of Processing Parameters on Aluminium Alloy A357 Manufactured by Selective Laser Melting, Mater. Des., 2016, 109, p 334–346. https://doi.org/10.1016/j.matdes.2016.07.00910.1016/j.matdes.2016.07.009 ↗
15. L.Z. Wang, S. Wang, and J.J. Wu, Experimental Investigation on Densification Behavior and Surface Roughness of AlSi10Mg Powders Produced by Selective Laser Melting, Opt. Laser Technol., 2017, 96, p 88–96. https://doi.org/10.1016/j.optlastec.2017.05.00610.1016/j.optlastec.2017.05.006 ↗
16. T. Kimura and T. Nakamoto, Microstructures and Mechanical Properties of A356 (AlSi7Mg0.3) Aluminum Alloy Fabricated by Selective Laser Melting, Mater. Des., 2016, 89, p 1294–1301. https://doi.org/10.1016/j.matdes.2015.10.06510.1016/j.matdes.2015.10.065 ↗
17. F. Trevisan, F. Calignano, M. Lorusso, J. Pakkanen, E.P. Ambrosio, L. Mariangela, M. Pavese, D. Manfredi and P. Fino, Effects of heat treatments on A357 alloy produced by selective laser melting, in World PM 2016 Congr. Exhib. (2016).
18. X. Zhang, J. Kang, Y. Rong, P. Wu, and T. Feng, Effect of Scanning Routes on the Stress and Deformation of Overhang Structures Fabricated by SLM, Materials (Basel), 2018 https://doi.org/10.3390/ma1201004710.3390/ma12010047 ↗
19. D. Buchbinder, W. Meiners, N. Pirch, K. Wissenbach, and J. Schrage, Investigation on Reducing Distortion by Preheating during Manufacture of Aluminum Components Using Selective Laser Melting, J. Laser Appl., 2014, 26, p 012004. https://doi.org/10.2351/1.482875510.2351/1.4828755 ↗
20. J. Fiocchi, A. Tuissi, P. Bassani, and C.A. Biffi, Low Temperature Annealing Dedicated to AlSi10Mg Selective Laser Melting Products, J. Alloys Compd., 2017, 695, p 3402–3409. https://doi.org/10.1016/j.jallcom.2016.12.01910.1016/j.jallcom.2016.12.019 ↗
21. J. Pezda, Optimization of Heat Treatment Parameters of AlSi7Mg Alloy, Materials (Basel), 2022, 15, p 9–12. https://doi.org/10.3390/ma1503116310.3390/ma15031163 ↗
22. L.F.L. Martins, P.R. Provencher, M. Brochu, and M. Brochu, Effect of Platform Temperature and Post-processing Heat Treatment on the Fatigue Life of Additively Manufactured AlSi7Mg Alloy, Metals (Basel), 2021 https://doi.org/10.3390/met1105067910.3390/met11050679 ↗
23. J.T.O. de Menezes, E.M. Castrodeza, L. Patriarca, and R. Casati, Effect of Heat Treatments and Loading Orientation on the Tensile Properties and Fracture Toughness of AlSi7Mg Alloy Produced by Laser Powder Bed Fusion, Int. J. Fract., 2022, 235, p 145–157. https://doi.org/10.1007/s10704-022-00631-510.1007/s10704-022-00631-5 ↗
24. T. Zou, M. Chen, H. Zhu, and S. Mei, Effect of Heat Treatments on Microstructure and Mechanical Properties of AlSi7Mg Fabricated by Selective Laser Melting, J. Mater. Eng. Perform., 2022, 31, p 1791–1802. https://doi.org/10.1007/s11665-021-06324-910.1007/s11665-021-06324-9 ↗
25. X. Ming, D. Song, A. Yu, H. Tan, Q. Zhang, Z. Zhang, J. Chen, and X. Lin, Effect of Heat Treatment on Microstructure, Mechanical and Thermal Properties of Selective Laser Melted AlSi7Mg Alloy, J. Alloys Compd., 2023, 945, p 169278. https://doi.org/10.1016/j.jallcom.2023.16927810.1016/j.jallcom.2023.169278 ↗
26. S. Cacace, A.G. Demir, G. Sala, and A.M. Grande, Influence of Production Batch Related Parameters on Static and Fatigue Resistance of LPBF Produced AlSi7Mg0.6, Int. J. Fatigue, 2022, 165, p 107227. https://doi.org/10.1016/j.ijfatigue.2022.10722710.1016/j.ijfatigue.2022.107227 ↗
27. M. Vanzetti, E. Virgillito, A. Aversa, D. Manfredi, F. Bondioli, M. Lombardi, and P. Fino, Short Heat Treatments for the F357 Aluminum Alloy Processed by Laser Powder Bed Fusion, Materials (Basel), 2021, 14, p 6157. https://doi.org/10.3390/ma1420615710.3390/ma14206157 ↗
28. J.Y. Hu, P. Liu, S.Y. Sun, Y.H. Zhao, Y.B. Zhang, and Y.S. Huo, Relation Between Heat Treatment Processes and Microstructural Characteristics of 7075 Al Alloy Fabricated by SLM, Vacuum, 2020, 177, p 109404. https://doi.org/10.1016/j.vacuum.2020.10940410.1016/j.vacuum.2020.109404 ↗
29. M. Tang, P.C. Pistorius, C. Montgomery, and J. Beuth, Build Rate Optimization for Powder Bed Fusion, J. Mater. Eng. Perform., 2019, 28, p 641–647. https://doi.org/10.1007/s11665-018-3647-510.1007/s11665-018-3647-5 ↗
30. D.S. MacKenzie, Heat Treatment Practice of Wrought Age-Hardenable Aluminum Alloys, Alum. Sci. Technol., 2018, 2, p 462–477. https://doi.org/10.31399/asm.hb.v02a.a000652010.31399/asm.hb.v02a.a0006520 ↗
31. V.A. Medrano, E. Arrieta, J. Merino, B. Ruvalcaba, K. Caballero, B. Ramirez, J. Diemann, L.E. Murr, R.B. Wicker, D. Godfrey, M. Benedict, and F. Medina, A Comprehensive and Comparative Study of Microstructure and Mechanical Properties for Post-process Heat Treatment of AlSi7Mg Alloy Components Fabricated in Different Laser Powder Bed Fusion Systems, J. Mater. Res. Technol., 2023, 24, p 6820–6842. https://doi.org/10.1016/j.jmrt.2023.04.12910.1016/j.jmrt.2023.04.129 ↗
32. H. Hyer, L. Zhou, S. Park, G. Gottsfritz, G. Benson, B. Tolentino, B. McWilliams, K. Cho, and Y. Sohn, Understanding the Laser Powder Bed Fusion of AlSi10Mg Alloy, Metallogr. Microstruct. Anal., 2020, 9, p 484–502. https://doi.org/10.1007/s13632-020-00659-w10.1007/s13632-020-00659-w ↗