A357 aluminium alloy produced by LPBF: Tribological behaviour in dry sliding conditions

Lorenzetti, Luca; Tonelli, Lavinia; Ceschini, Lorella; Liverani, Erica; Martini, Carla

doi:10.1016/j.wear.2022.204488

Cited by 5 publications

(3 citation statements)

References 34 publications

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“… Plot of surface roughness as a function of the main categories of commercially available materials for PBF-LB/M production [ 130 , 131 , 132 , 133 , 134 , 135 , 136 , 137 , 138 , 139 , 140 , 141 , 142 , 143 , 144 , 145 , 146 , 147 , 148 , 149 , 150 , 151 , 152 , 153 , 154 , 155 , 156 , 157 , 158 , 159 , 160 , 161 , 162 , 163 ]. …”

Section: Figurementioning

confidence: 99%

Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review

2023

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Their high strength-to-weight ratio, good corrosion resistance and excellent thermal and electrical conductivity have exponentially increased the interest in aluminium alloys in the context of laser-based powder bed fusion (PBF-LB/M) production. Although Al-based alloys are the third most investigated category of alloys in the literature and the second most used in industry, their processing by PBF-LB/M is often hampered by their considerable solidification shrinkage, tendency to oxidation, high laser reflectivity and poor powder flowability. For these reasons, high-strength Al-based alloys traditionally processed by conventional procedures have often proved to be unprintable with additive technology, so the design and development of new tailored Al-based alloys for PBF-LB/M production is necessary. The aim of the present work is to explore all the challenges encountered before, during and after the PBF-LB/M processing of Al-based alloys, in order to critically analyse the solutions proposed in the literature and suggest new approaches for addressing unsolved problems. The analysis covers the critical aspects in the literature as well as industrial needs, industrial patents published to date and possible future developments in the additive market.

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Section: Figurementioning

confidence: 99%

Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review

2023

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“…In fact, their printability is affected by several features such as high reflectivity, high thermal conductivity, and poor flowability of the powder [7]. Among traditional Al alloys, near-eutectic cast alloys such as AlSi10Mg [8][9][10][11][12][13], AlSi12 [14,15], and A357 [16][17][18] are the most studied and suitable for LPBF [2]. This is due to the high Si content, which improves both the processability and the printability of these alloys by enhancing the fluidity of the melted alloy, narrowing the solidification range [19], and increasing the fraction of absorbed energy [2].…”

Section: Introductionmentioning

confidence: 99%

Processability of A6061 Aluminum Alloy Using Laser Powder Bed Fusion by In Situ Synthesis of Grain Refiners

Rosito

Vanzetti

Padovano

et al. 2023

Metals

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Despite the increasing interest in laser powder bed fusion (LPBF), only a few cast aluminum alloys are available for this process. This study focuses on improving the LPBF processability of the A6061 alloy, which is challenging due to its wide solidification range, the dendritic columnar grain growth, and consequent solidification cracking. To address these issues, in situ-synthesized grain refiners can be used to induce equiaxial grain growth and prevent crack formation. A6061 RAM2 powder—a mixture of A6061, Ti, and B4C—was characterized and processed using a low-power LPBF machine to create an in situ particle-reinforced metal matrix composite. Parameter optimization was performed to evaluate the effect of their variation on the printability of the alloy. Microstructural characterization of the samples revealed that the complete reaction and the synthesis of the ceramic reinforcement did not occur. However, TiAl3 was synthesized during the process and promoted a partial grain refinement, leading to the formation of equiaxial grains and preventing the formation of solidification cracks. The tensile tests carried out on the optimized samples exhibit superior mechanical properties compared to those of A6061 processed through LPBF.

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“…Çolak et al [19] studied the effects of grain refiner and modifier additives on tribological properties of A357 aluminum alloys, demonstrating that Al5Ti1B grain refiner and Al10Sr modifier additives could decrease the friction coefficient and increase the wear resistance significantly. Lorenzetti et al [20] studied the wear performance of AlSi7Mg0.6 alloy produced by LPBF technique, where the refined microstructure decreased the wear rate compared with conventional processing techniques. Except the wear performance of the matrix material, several studies were also conducted on A357 composites reinforced with different particles.…”

Section: Introductionmentioning

confidence: 99%

Influence of Applied Load and Sliding Distance on Wear Performance of AlSi7Mg0.6 Aluminum Alloy

Zhang,

Zhao,

Pan

et al. 2023

Metals

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The wear performance of AlSi7Mg0.6 aluminum alloy, a casting aluminum alloy used in positioning devices for catenary systems of high-speed railways which fail frequently on lines where the speed of trains is higher than 300 m/s, is discussed in this study. It was estimated that sliding contact wear occurred and mainly contributed to the failure. To explore the competing mechanism for frictional wear failure, frictional experiments based on three groups of sliding distance (0.5 mm, 1.5 mm and 3.0 mm) and four groups of applied loads (20 N, 50 N, 100 N and 200 N) were implemented. Three-dimensional morphological observation results revealed that the wear volumes at a sliding distance of 0.5 mm were only about 1/10 of that at a sliding distance of 3.0 mm. It was also revealed that the wear volume based on a sliding distance of 3.0 mm and applied load of 20 N was still much larger than the wear volume under a sliding distance of 0.5 mm and applied load of 200 N. SEM observation of the microstructures revealed that abrasive wear was the dominant wear mechanism in dry sliding friction conditions. A simplified positioning device model was also established to study the influence of tension force on wear performance. The simulation results revealed that smaller tension force between the positioning support and positioning hook would lead to higher relative sliding distance and larger wear depth. Sliding contact friction should be avoided due to relatively large wear efficiency compared with rolling contact friction. Both experimental and simulation results suggested that proper tension force was preferred in assembling components which could ensure rolling contact friction rather than sliding contact friction.

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A357 aluminium alloy produced by LPBF: Tribological behaviour in dry sliding conditions

Cited by 5 publications

References 34 publications

Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review

Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review

Processability of A6061 Aluminum Alloy Using Laser Powder Bed Fusion by In Situ Synthesis of Grain Refiners

Influence of Applied Load and Sliding Distance on Wear Performance of AlSi7Mg0.6 Aluminum Alloy

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