In this study, the evolution of mechanical properties, microstructure, and residual stresses during selective laser melting of CuSn10 components was studied. To provide a proper material model for the simulations, various CuSn10 parts were manufactured using selective laser melting and examined. The manufactured parts were also used to validate the developed model. Subsequently, a sequentially coupled thermal–mechanical FEM model was developed using the Ansys software package. The developed model was able to deliver the mechanical properties, residual stresses, and microstructure of the additively manufactured components. Due to introducing some simplifications to the model, a calibration factor was applied to adjust the simulation results. However, the developed model was validated and showed a good agreement with the experimental results, such as measured residual stresses using the hole drilling method, as well as mechanical properties of manufactured parts. Moreover, the developed material model was used to simulate the microstructure of manufactured CuSn10. A fine-grain microstructure with an average diameter of 19 ± 11 μm and preferred orientation in the Z-direction, which was the assembly direction, was obtained.
Research and industry are calling for additively manufactured multi-materials, as these are expected to create more efficient components, but there is a lack of information on corrosion resistance, especially since there is a risk of bimetallic corrosion with two metallic components. In this study, the corrosion behaviour of a multi-material made of 316L and CuSn10 is investigated before and after a stress relief annealing using linear sweep voltammetry. For this purpose, a compromise had to be found in the heat treatment parameters in order to be able to treat both materials together. In addition, additively manufactured and rolled samples were investigated and used as a reference. Interaction of the two materials in the multi-material could be demonstrated, but further investigations are necessary to clearly assess the behaviour. In particular, the transition region of the two materials should be investigated. In this study, a stress relief heat treatment at 400 °C caused a slight improvement in the corrosion resistance and reduced the scatter of the measurements significantly. No significant difference was measured between the additively produced and rolled samples.
CuSn10 alloy, has remarkable mechanical properties, including good elongation and medium hardness. Additive manufacturing of this powder compound is developing on a fast slope. In this paper, the optimization of the process parameters of the Selective Laser Melting (SLM) method was carried out to manufacture CuSn10 compounds. In addition, a numerical model for the simulation of the melt pool behaviour was created by utilizing Ansys 2021 R1 software, and a comparison was carried out between predicted numerical data with achieved experimental results. The formation conditions of various melt traces were modelled, measured, and validated for this aim. In the experimental stage, a constant laser power of 95 W was used, and the effect of variation of the scanning speed was studied between 10 to 1500 mm.s−1. Results showed that the variation of the scanning speed is not enough, and optimisation must be applied by participating in other process parameters. It indicates that by adjusting the process parameters to have a 365 W power, the liquid phase can be achieved in the production process.
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