Microstructural and mechanical properties of AlSi10Mg: Hybrid welding of additively manufactured and cast parts
Source abstract
Abstract
Abstract Welding and joining of hybrid components consisting of additively manufactured (AM) parts and conventionally processed parts offer new opportunities in structural design. In the present study, AlSi10Mg specimens were fabricated using two different manufacturing processes, i.e., laser-based powder-bed fusion of metals (PBF-LB/M) and casting, and welded by means of friction stir welding (FSW). Material strength of dissimilar welded joints was found to be governed by the as-cast material, which is characterized by a very coarse microstructure resulting in inferior hardness and tensile properties. During fatigue testing, cast-cast specimens performed slightly better than their hybrid AM-cast counterparts with respect to lifetime, being rationalized by most pronounced strain inhomogeneities in the AM-cast specimens. With the aim of cost reduction, FSW can be employed to fabricate graded large parts as long as the AM as-built material is placed in the region demanding superior cyclic load-bearing capacity. Graphical abstract
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Additive Manufacturing Materials and Processes · Additive Manufacturing and 3D Printing Technologies · Advanced Welding Techniques Analysis
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (49)
Show source-provided references
1. B. Chen, S.K. Moon, X. Yao, G. Bi, J. Shen, J. Umeda, K. Kondoh, Scr. Mater. 141, 45 (2017). https://doi.org/10.1016/J.SCRIPTAMAT.2017.07.02510.1016/J.SCRIPTAMAT.2017.07.025 ↗
2. C.Y. Yap, C.K. Chua, Z.L. Dong, Z.H. Liu, D.Q. Zhang, L.E. Loh, S.L. Sing, Appl. Phys. Rev. 2, 41101 (2015). https://doi.org/10.1063/1.493592610.1063/1.4935926 ↗
3. J. Zhang, B. Song, Q. Wei, D. Bourell, Y. Shi, J. Mater. Sci. Technol. 35, 270 (2019). https://doi.org/10.1016/j.jmst.2018.09.00410.1016/j.jmst.2018.09.004 ↗
4. G. Moeini, S.V. Sajadifar, T. Wegener, C. Rössler, A. Gerber, S. Böhm, T. Niendorf, J. Mater. Res. Technol. 12, 1446 (2021). https://doi.org/10.1016/j.jmrt.2021.03.10110.1016/j.jmrt.2021.03.101 ↗
5. A. Mertens, J. Delahaye, O. Dedry, B. Vertruyen, J.T. Tchuindjang, A.M. Habraken, Procedia Manuf. 47, 1089 (2020). https://doi.org/10.1016/j.promfg.2020.04.12110.1016/j.promfg.2020.04.121 ↗
6. F. Trevisan, F. Calignano, M. Lorusso, J. Pakkanen, A. Aversa, E.P. Ambrosio, M. Lombardi, P. Fino, D. Manfredi, Materials (2017). https://doi.org/10.3390/ma1001007610.3390/ma10010076 ↗
7. Q. Yan, B. Song, Y. Shi, J. Mater. Sci. Technol. 41, 199 (2020). https://doi.org/10.1016/j.jmst.2019.08.04910.1016/j.jmst.2019.08.049 ↗
8. J. Suryawanshi, K.G. Prashanth, S. Scudino, J. Eckert, O. Prakash, U. Ramamurty, Acta Mater. 115, 285 (2016). https://doi.org/10.1016/j.actamat.2016.06.00910.1016/j.actamat.2016.06.009 ↗
9. C. Emmelmann, P. Sander, J. Kranz, E. Wycisk, Phys. Procedia 12, 364 (2011). https://doi.org/10.1016/j.phpro.2011.03.04610.1016/j.phpro.2011.03.046 ↗
10. M. Nahmany, I. Rosenthal, I. Benishti, N. Frage, A. Stern, Addit. Manuf. 8, 63 (2015). https://doi.org/10.1016/j.addma.2015.08.00210.1016/j.addma.2015.08.002 ↗
11. G. Moeini, S.V. Sajadifar, T. Wegener, F. Brenne, T. Niendorf, S. Böhm, Mater. Sci. Eng. A 764, 138189 (2019). https://doi.org/10.1016/j.msea.2019.13818910.1016/j.msea.2019.138189 ↗
12. Z. Du, M.J. Tan, H. Chen, G. Bi, C.K. Chua, Weld World 62, 675 (2018). https://doi.org/10.1007/s40194-018-0585-710.1007/s40194-018-0585-7 ↗
13. F. Scherillo, A. Astarita, U. Prisco, V. Contaldi, P. Di Petta, A. Langella, A. Squillace, Metallogr. Microstruct. Anal. 7, 457 (2018). https://doi.org/10.1007/s13632-018-0465-y10.1007/s13632-018-0465-y ↗
14. Z. Du, H.-C. Chen, M.J. Tan, G. Bi, C.K. Chua, J. Manuf. Process. 36, 33 (2018). https://doi.org/10.1016/j.jmapro.2018.09.02410.1016/j.jmapro.2018.09.024 ↗
15. A.E. Hassanin, C. Velotti, F. Scherillo, A. Astarita, A. Squillace, L. Carrino, in 2017 IEEE 3rd International Forum on Research and Technologies for Society and Industry (RTSI), IEEE (2017), p. 110.1109/RTSI.2017.8065967 ↗
16. K.G. Prashanth, R. Damodaram, S. Scudino, Z. Wang, K. Prasadao, J. Eckert, Mater. Des. 57, 632 (2014). https://doi.org/10.1016/j.matdes.2014.01.02610.1016/j.matdes.2014.01.026 ↗
17. L. Zhao, J.G. Santos Macías, L. Ding, H. Idrissi, A. Simar, Mater. Sci. Eng. A 764, 138210 (2019). https://doi.org/10.1016/j.msea.2019.13821010.1016/j.msea.2019.138210 ↗
18. G. Moeini, S.V. Sajadifar, T. Engler, B. Heider, T. Niendorf, M. Oechsner, S. Böhm, Metals 10, 85 (2020). https://doi.org/10.3390/met1001008510.3390/met10010085 ↗
19. W.W. Wits, J.J. Becker, Procedia CIRP 28, 70 (2015). https://doi.org/10.1016/j.procir.2015.04.01310.1016/j.procir.2015.04.013 ↗
20. A. Ascari, A. Fortunato, E. Liverani, A. Gamberoni, L. Tomesani, Phys. Procedia 83, 839 (2016). https://doi.org/10.1016/j.phpro.2016.08.08710.1016/j.phpro.2016.08.087 ↗
21. M. Besel, Y. Besel, U. Alfaro Mercado, T. Kakiuchi, Y. Uematsu, Int. J. Fatigue 77, 1 (2015). https://doi.org/10.1016/j.ijfatigue.2015.02.01310.1016/j.ijfatigue.2015.02.013 ↗
22. M. Cabibbo, A. Forcellese, E. Santecchia, C. Paoletti, S. Spigarelli, M. Simoncini, Metals 10, 233 (2020). https://doi.org/10.3390/met1002023310.3390/met10020233 ↗
23. L. Thijs, K. Kempen, J.-P. Kruth, J. van Humbeeck, Acta Mater. 61, 1809 (2013). https://doi.org/10.1016/j.actamat.2012.11.05210.1016/j.actamat.2012.11.052 ↗
24. J. Richter, S.V. Sajadifar, T. Niendorf, Addit. Manuf. 47, 102346 (2021). https://doi.org/10.1016/j.addma.2021.10234610.1016/j.addma.2021.102346 ↗
25. R.L. Xin, B. Li, Q. Liu, MSF 654–656, 1195 (2010). https://doi.org/10.4028/www.scientific.net/MSF.654-656.119510.4028/www.scientific.net/MSF.654-656.1195 ↗
26. O. Gursoy, G. Timelli, J. Mater. Res. Technol. 9, 8652 (2020). https://doi.org/10.1016/j.jmrt.2020.05.10510.1016/j.jmrt.2020.05.105 ↗
27. S. Seifeddine, T. Sjgren, I.L. Svensson, Metall. Sci. Technol. 25 (2007)
28. M. Neuser, O. Grydin, Y. Frolov, M. Schaper, Prod. Eng. Res. Dev. (2022). https://doi.org/10.1007/s11740-022-01106-110.1007/s11740-022-01106-1 ↗
29. T. Niendorf, Diss., Ermüdungseigenschaften ultrafeinkörniger kubisch raumzentrierter Werkstoffe: Einfluss der Mikrostruktur (2010)
30. T. Niendorf, C. Lotze, D. Canadinc, A. Frehn, H.J. Maier, Mater. Sci. Eng. A 499, 518 (2009). https://doi.org/10.1016/j.msea.2008.09.03310.1016/j.msea.2008.09.033 ↗
31. Z. Zhang, Z. Hu, S. Schmauder, M. Mlikota, K. Fan, J. Mater. Eng. Perform. 25, 1650 (2016). https://doi.org/10.1007/s11665-016-1977-810.1007/s11665-016-1977-8 ↗
32. S.V. Sajadifar, G.G. Yapici, E. Demler, P. Krooß, T. Wegener, H.J. Maier, T. Niendorf, Int. J. Fatigue 122, 228 (2019). https://doi.org/10.1016/j.ijfatigue.2019.01.02110.1016/j.ijfatigue.2019.01.021 ↗
33. S. Picak, T. Wegener, S.V. Sajadifar, C. Sobrero, J. Richter, H. Kim, T. Niendorf, I. Karaman, Acta Mater. 205, 116540 (2021). https://doi.org/10.1016/j.actamat.2020.11654010.1016/j.actamat.2020.116540 ↗
34. S. Romano, L. Patriarca, S. Foletti, S. Beretta, Int. J. Fatigue 117, 47 (2018). https://doi.org/10.1016/j.ijfatigue.2018.07.03010.1016/j.ijfatigue.2018.07.030 ↗
35. C. Fischer, C. Schweizer, MATEC Web Conf. 326, 7003 (2020). https://doi.org/10.1051/matecconf/20203260700310.1051/matecconf/202032607003 ↗
36. D. Ovono Ovono, I. Guillot, D. Massinon, J. Alloys Compd. 452, 425 (2008). https://doi.org/10.1016/j.jallcom.2006.11.05210.1016/j.jallcom.2006.11.052 ↗
37. M. Tiryakioğlu, On fatigue life variability in cast Al–10%Si–Mg alloys. Mater. Sci. Eng. 527, 1560 (2010)10.1016/j.msea.2009.10.027 ↗
38. Q.G. Wang, P.N. Crepeau, C.J. Davidson, J.R. Griffiths, Metall. Mater. Trans. B 37, 887 (2006). https://doi.org/10.1007/BF0273501010.1007/BF02735010 ↗
39. G. Sigworth, Int. J. Metalcast. 5, 7 (2011). https://doi.org/10.1007/BF0335550410.1007/BF03355504 ↗
40. Q. Wang, D. Apelian, D. Lados, J. Light Met. 1, 85 (2001). https://doi.org/10.1016/S1471-5317(00)00009-210.1016/S1471-5317(00)00009-2 ↗
41. Q. Wang, D. Apelian, D. Lados, J. Light Met. 1, 73 (2001). https://doi.org/10.1016/S1471-5317(00)00008-010.1016/S1471-5317(00)00008-0 ↗
42. M. Tang, P.C. Pistorius, Int. J. Fatigue 94, 192 (2017). https://doi.org/10.1016/j.ijfatigue.2016.06.00210.1016/j.ijfatigue.2016.06.002 ↗
43. J. Fan, D.L. McDowell, M.F. Horstemeyer, K. Gall, Eng. Fract. Mech. 70, 1281 (2003). https://doi.org/10.1016/S0013-7944(02)00097-810.1016/S0013-7944(02)00097-8 ↗
44. Y. Birol, A.A. Ebrinc, Int. J. Cast Met. Res. 21, 408 (2008). https://doi.org/10.1179/136404608X37074710.1179/136404608X370747 ↗
45. K.S. Chan, P. Jones, Q. Wang, Mater. Sci. Eng. A 341, 18 (2003). https://doi.org/10.1016/S0921-5093(02)00196-X10.1016/S0921-5093(02)00196-X ↗
46. Rheinfelden AllOYS, Primary Aluminium Alloys for Pressure die Casting, https://rheinfelden-alloys.eu/wp-content/uploads/2016/01/05-HB-DG_Ci_Sf_Cm_Td_Ma_RHEINFELDEN-ALLOYS_2015_EN.pdf. Accessed 12 Oct 2022
47. T. Wegener, J. Koopmann, J. Richter, P. Krooß, T. Niendorf, Fatigue Fract. Eng. Mater. Struct. 44, 2570 (2021). https://doi.org/10.1111/ffe.1352710.1111/ffe.13527 ↗
48. T. Wegener, F. Brenne, A. Fischer, T. Möller, C. Hauck, S. Auernhammer, T. Niendorf, Addit. Manuf. 37, 101603 (2021). https://doi.org/10.1016/j.addma.2020.10160310.1016/j.addma.2020.101603 ↗
49. T. Wegener, J. Günther, F. Brenne, T. Niendorf, in Structural Integrity of Additive Manufactured Parts, ed. by N. Shamsaei, S. Daniewicz, N. Hrabe, S. Beretta, J. Waller, M. Seifi (ASTM International, West Conshohocken, 2020), p. 465. https://doi.org/10.1520/STP16202018010810.1520/STP162020180108 ↗