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Additive manufacturing offers unique possibilities to produce complex components, which would not be possible or only very difficult to be realizable with conventional manufacturing processes. The potential of additive manufacturing of aluminum alloys has already been realized in prototyping, but still offers potential in the establishment of series applications. For enabling the establishment of additive manufacturing in series applications, comprehensive knowledge about the material behavior is necessary. This study examines the torsional behavior of additive manufactured AlSi10Mg samples and shows the correlation between tensile and torsional strength. Comprehensive torsion tests with strain gauges were performed and significant directional dependencies were shown. The correlation factor in the area of torsional yield strength/tensile yield strength and torsional strength/tensile strength was determined and was compared with the yield/failure conditions according to Tresca and von Mises.
Das Interesse der Industrie an additiv gefertigten Bauteilen steigt z unehmend, wobei mit zunehmendem Verständnis der statischen Kennwerte nunmehr der Fokus in Richtung der dynamischen Festigkeiten wandert. Deswegen werden Einflussparameter auf die Lebensdauer und potenzielle Nachbearbeitungsmethoden untersucht und analysiert. Ein großer Einfluss ist dabei der Oberflächengüte und den durch Rautiefen initiierten Kerbeffekten zuzuschreiben. Deswegen werden unterschiedliche Methoden zur Verbesserung der Oberflächengüte untersucht. Dabei werden die Verfahren Laserpolieren, elektrochemisches Polieren und Hartmetallkugelstrahlen und deren Auswirkung auf Oberflächengüte sowie Härte untersucht. Für das elektrochemische Polieren werden die Proben in einer Perchlorsäure für 90 s bei 32 V und maximal 10 A poliert. Das Hartmetallkugelstrahlen wird mit einem UFS 100 Strahlmittel bei einem Druck von 4 bar und einer Strahldauer von 10 s ausgeführt. Anschließend werden Wöhlerlinien für die unterschiedlichen Zustände mittels Umlaufbiegeversuch ermittelt, welche mit Referenzwerten analysierter konventioneller Proben verglichen werden. Des Weiteren werden die Bruchflächen analysiert. Die Untersuchungen ergaben ein hohes Optimierungspotenzial der additiv gefertigten Proben bei einer Verdichtung der Oberfläche sowie einer Entfernung der Randschicht durch eine spanende Bearbeitung. Dadurch wurden höhere Zeitfestigkeiten als mit konventionell gefertigten Proben erreicht.
Laser powder bed fusion has become one of the major techniques within metal additive manufacturing, especially when delicate structures and high geometric accuracy are concerned. Lately, the awareness of the material-specific macroscopic anisotropy has risen and led to widespread investigations on the static mechanical strength. However, little is known about the fracture behavior of the layer-wise fabricated metal components and their affinity of crack propagation between consecutive layers, which is particularly important for aluminium–silicon alloys containing embrittled zones in double-irradiated areas. A recent study indicated that there is a significant drop in fracture toughness in case the crack growth direction is parallel to the layering. To investigate this matter further and to shed light on the fracture toughness behavior in the range of a 0°–45° angle offset between the crack growth direction relative to the layering, notched samples with varying polar angles were subjected to mode I fracture toughness testing. Our results indicate that the fracture toughness is an almost-stable characteristic up to a mismatch of about 20° between the crack propagation path and the layering, at which point the fracture toughness decreases by up to 10%.
Laser powder-bed fusion (LPBF) has significantly gained in importance and has become one of the major fabrication techniques within metal additive manufacturing. The fast cooling rates achieved in LPBF due to a relatively small melt pool on a much larger component or substrate, acting as heat sink, result in fine-grained microstructures and high oversaturation of alloying elements in the α-aluminum. Al-Si-Mg alloys thus can be effectively precipitation hardened. Moreover, the solidified material undergoes an intrinsic heat treatment, whilst the layers above are irradiated and the elevated temperature in the built chamber starts the clustering process of alloying elements directly after a scan track is fabricated. These silicon-magnesium clusters were observed with atom probe tomography in as-built samples. Similar beneficial clustering behavior at higher temperatures is known from the direct-aging approach in cast samples, whereby the artificial aging is performed immediately after solution annealing and quenching. Transferring this approach to LPBF samples as a possible post-heat treatment revealed that even after direct aging, the outstanding hardness of the as-built condition could, at best, be met, but for most instances it was significantly lower. Our investigations showed that LPBF Al-Si-Mg exhibited a high dependency on the quenching rate, which is significantly more pronounced than in cast reference samples, requiring two to three times higher quenching rate after solution annealing to yield similar hardness results. This suggests that due to the finer microstructure and the shorter diffusion path in Al-Si-Mg fabricated by LPBF, it is more challenging to achieve a metastable oversaturation necessary for precipitation hardening. This may be especially problematic in larger components.
Hot isostatic pressing can be utilized to reduce the anisotropic mechanical properties of Al–Si–Mg alloys fabricated by laser powder-bed fusion (L-PBF). The implementation of post processing densification processes can open up new fields of application by meeting high quality requirements defined by aircraft and automotive industries. A gas pressure of 75 MPa during hot isostatic pressing lowers the critical cooling rate required to achieve a supersaturated solid solution. Direct aging uses this pressure related effect during heat treatment in modern hot isostatic presses, which offer advanced cooling capabilities, thereby avoiding the necessity of a separate solution annealing step for Al–Si–Mg cast alloys. Hot isostatic pressing, followed by rapid quenching, was applied to both sand cast as well as laser powder-bed fused Al–Si–Mg aluminum alloys. It was shown that the critical cooling rate required to achieve a supersaturated solid solution is significantly higher for additively manufactured, age-hardenable aluminum alloys than it is for comparable sand cast material. The application of hot isostatic pressing can be combined with heat treatment, consisting of solution annealing, quenching and direct aging, in order to achieve both a dense material with a small number of preferred locations for the initiation of fatigue cracks and a high material strength.
Metal additive manufacturing of dental prostheses consisting of cobalt−chromium−tungsten (Co−Cr−W) alloys poses an alternative to investment casting. However, metal additive manufacturing processes like Laser Powder‐Bed Fusion (LPBF) can impact the elastic constants and the mechanical anisotropy of the resulting material. To investigate the phase compositions of mechanically different specimens in dependence of their postprocessing steps (e. g. heat treatment to relieve stress), the current study uses X‐ray Diffraction (XRD), Electron BackScatter Diffraction (EBSD), and Transmission Electron Microscopy (TEM) for phase identification. Our studies connect plastic deformation of Remanium star CL alloy with the formation of the hexagonal ϵ‐phase and heat treatment with the formation of the D024‐phase, while partially explaining previously observed differences in Young's moduli.
Laser powder-bed fusion has become one of the most important techniques in additive manufacturing. For guaranteeing the possibility of manufacturing highly specialized and advanced components, currently intensive research is carried out in this field. One area of this research is the material-specific macroscopic anisotropy, which is investigated in our work by comprehensive static mechanical experiments. The material which was tested within this study was the precipitation-hardenable AlSi10Mg alloy, with the focus on installation space orientation. Tensile and compression tests were performed, the results for the Young's modulus in compressive loading exceeded the previously known values of this material in tensile loading and achieved values of up to 79.8 GPa. As a result of this investigation, a chemical spectroscopic analysis was undertaken and from the actual chemical composition, a relative density of 99.86% of the samples was determined.