A hybrid framework to estimate the surface state and fatigue performance of laser powder bed fusion materials after shot peening
Source abstract
Abstract
Abstract Despite the rapid growth of additive manufacturing (AM) technologies, AM parts usually present relatively poor surface quality in as-built condition. This necessitates the application of customized post surface treatments to efficiently enhance the surface quality and alleviate the adverse effects of high surface roughness and extremely irregular surface morphology on fatigue strength of AM metallic materials. In this paper, starting from an as-built AM surface, a detailed numerical model is developed to effectively estimate the surface morphology of laser powder bed fusion (LPBF) AlSi10Mg specimens after shot peening. The obtained results are then incorporated into two analytical approaches to evaluate the fatigue strength of different series. The accuracy of the model is validated by comparisons made with experimental data obtained considering as-built and shot peened specimens both before and after heat treatment. The results demonstrate that the proposed hybrid approach can serve as a powerful package not only to determine the beneficial contribution of shot peening on the surface morphology of AM material but also to provide an accurate and rather reliable approximation of their fatigue strength.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Additive Manufacturing Materials and Processes · Surface Treatment and Residual Stress · Additive Manufacturing and 3D Printing Technologies
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (46)
Show source-provided references
1. Random 3D-printed isotropic composites with high volume fraction of pore-like polydisperse inclusions and near-optimal elastic stiffness10.1016/j.actamat.2019.06.020 ↗
2. Numerically-aided 3D printed random isotropic porous materials approaching the Hashin-Shtrikman bounds10.1016/j.compositesb.2018.08.032 ↗
3. Costs and cost effectiveness of additive manufacturing
4. Mechanical behavior of additive manufactured, powder-bed laser-fused materials10.1016/j.msea.2015.10.068 ↗
5. Fatigue strength assessment of “as built” AlSi10Mg manufactured by SLM with different build orientations10.1016/j.ijfatigue.2020.105737 ↗
6. Numerical modelling of surface roughness effect on the fatigue behavior of Ti-6Al-4V obtained by additive manufacturing10.1016/j.ijfatigue.2019.02.014 ↗
7. Analysis of the effect of surface roughness on fatigue performance of powder bed fusion additive manufactured metals10.1016/j.tafmec.2020.102638 ↗
8. Z. Chen, S. Cao, X. Wu, C.H.J. Davies, 13 - Surface roughness and fatigue properties of selective laser melted Ti–6Al–4V alloy, in Additive Manufacturing for the Aerospace Industry, in: F. Froes, R. Boyer (Eds.), Elsevier, 2019. p. 283–299.10.1016/B978-0-12-814062-8.00015-7 ↗
9. Fatigue life estimation of additive manufactured parts in the as-built surface condition
10. An examination of the effects from surface texture on the strength of fiber reinforced plastics10.1177/002199839903300201 ↗
11. Surface post-treatments for metal additive manufacturing: Progress, challenges, and opportunities
12. Enhancing the Structural Performance of Lightweight Metals by Shot Peening10.1002/adem.201801140 ↗
13. On the fatigue strength enhancement of additive manufactured AlSi10Mg parts by mechanical and thermal post-processing10.1016/j.matdes.2018.02.055 ↗
14. Influence of Shot Peening on AlSi10Mg Parts Fabricated by Additive Manufacturing
15. Improved fatigue strength of additively manufactured Ti6Al4V by surface post processing10.1016/j.ijfatigue.2020.105497 ↗
16. High Cycle Fatigue (HCF) Performance of Ti-6Al-4V Alloy Processed by Selective Laser Melting10.4028/www.scientific.net/AMR.816-817.134 ↗
17. Effect of surface treatment on the fatigue strength of additive manufactured Ti6Al4V alloy10.3221/IGF-ESIS.53.26 ↗
18. Effect of Various Peening Methods on the Fatigue Properties of Titanium Alloy Ti6Al4V Manufactured by Direct Metal Laser Sintering and Electron Beam Melting10.3390/ma13102216 ↗
19. The effect of post-sintering treatments on the fatigue and biological behavior of Ti-6Al-4V ELI parts made by selective laser melting10.1016/j.jmbbm.2017.03.024 ↗
20. The microstructure and mechanical properties of selectively laser melted AlSi10Mg: The effect of a conventional T6-like heat treatment10.1016/j.msea.2016.04.092 ↗
21. Corrosion behavior of friction stir welded lap joints of AA6061-T6 aluminum alloy10.1590/S1516-14392014005000053 ↗
22. A numerical model of severe shot peening (SSP) to predict the generation of a nanostructured surface layer of material10.1016/j.surfcoat.2010.05.035 ↗
23. An area-average approach to peening residual stress under multi-impacts using a three-dimensional symmetry-cell finite element model with plastic shots10.1016/j.matdes.2009.07.032 ↗
24. Relating Almen intensity to residual stresses induced by shot peening: a numerical approach10.1016/S0924-0136(00)00893-1 ↗
25. 1909
26. Effect of shot peening coverage on hardness, residual stress and surface morphology of carburized rollers10.1016/j.surfcoat.2019.125273 ↗
27. Effects of different shot peening parameters on residual stress, surface roughness and cell size10.1016/j.surfcoat.2020.126054 ↗
28. Effect of shot peening coverage on residual stress and surface roughness of 18CrNiMo7-6 steel10.1016/j.ijmecsci.2020.105785 ↗
29. On the potential applications of a 3D random finite element model for the simulation of shot peening10.1016/j.advengsoft.2009.03.013 ↗
30. Roughness parameters10.1016/S0924-0136(02)00060-2 ↗
31. W.J. Dixon, F.J. Massey Jr, Introduction to statistical analysis, in: Introduction to statistical analysis, McGraw-Hill, New York, NY, US, 1951. x, 370-x, 370.
32. Estimating the fatigue stress concentration factor of machined surfaces10.1016/S0142-1123(02)00012-9 ↗
33. Surface finish effect on fatigue behavior of forged steel10.1016/j.ijfatigue.2011.08.008 ↗
34. J.A. Greenwood, K.L. Johnson, A unified theory of surface roughness, Proc. Roy. Soc. London. A. Math. Phys. Sci. 393(1804) (1984) 133–157.10.1098/rspa.1984.0050 ↗
35. Surface roughness analysis of glass-ceramic substrates and finished magnetic disks, and Ni-P coated Al-Mg and glass substrates10.1016/0043-1648(95)06764-7 ↗
36. N.E. Dowling, Mechanical behavior of materials : engineering methods for deformation, fracture, and fatigue, Prentice Hall, Englewood Cliffs, N.J., [1993] ©1993, 1993.
37. R.W. Karry, T.J. Dolan, S. Illinois, Univ at urbana engineering experiment, in: Influence of grain size on fatigue notch-sensitivity. Ft. Belvoir: Defense Technical Information Center, 1953.
38. Thermal post-processing of AlSi10Mg parts produced by Selective Laser Melting using recycled powder
39. Fatigue analysis by local stress concept based on finite element results10.1016/S0045-7949(02)00273-0 ↗
40. Fatigue of metals. P. G. Forrest. Oxford 1962, Pergamon Press Ltd., 425 S., 154 Abb., 84 Tab., Preis sh 70.–. Materials and Corrosion, 1963. 14(7): p. 630-630.10.1002/maco.19630140711 ↗
41. L. Tóth, S.Y. Yarema, Formation of the science of fatigue of metals. Part 1. 1825–1870, Mater. Sci. 42(5) (2006) 673–680.10.1007/s11003-006-0132-3 ↗
42. Lebensdauervorhersage auf Basis von Finite Elemente Ergebnissen10.1002/mawe.200300665 ↗
43. Numerical and experimental analysis of surface roughness generated by shot peening10.1016/j.apsusc.2012.03.111 ↗
44. Discrete element-periodic cell coupling model and investigations on shot stream expansion, Almen intensities and target materials10.1016/j.ijmecsci.2018.06.023 ↗
45. Application of different fatigue strength criteria on shot peened notched parts. Part 2: nominal and local stress approaches10.1016/j.apsusc.2013.10.130 ↗
46. How to determine the number of asperity peaks, their radii and their heights for engineering surfaces: A critical appraisal10.1016/j.wear.2013.01.105 ↗