Deformation and fatigue behaviour of additively manufactured Scalmalloy® with bimodal microstructure

Schimbäck, D.; Kaserer, Lukas; Mair, Philipp; Palm, Frank; Leichtfried, Gerhard; Pogatscher, Stefan; Hohenwarter, Anton

doi:10.1016/j.ijfatigue.2023.107592

International Journal of Fatigue

2023

DOI: 10.1016/j.ijfatigue.2023.107592

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Deformation and fatigue behaviour of additively manufactured Scalmalloy® with bimodal microstructure

D. Schimbäck

Lukas Kaserer

Philipp Mair

et al.

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Cited by 10 publications

References 64 publications

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Microstructures and mechanical properties of friction stir welded additively manufactured Scalmalloy®

Mirandola,

Novel,

Perini

et al. 2024

Int J Adv Manuf Technol

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The development of high-strength advanced additively manufactured (AM) aluminum alloys is driven by the need for weight reduction in complex-shaped structural applications. In this context, heat-treatable aluminum-scandium alloy, known commercially as Scalmalloy®, offers high strength and lightness, also at high temperatures, due to solution strengthening Al3(Sc, Zr) particles. A widespread diffusion of such AM alloy is also related to welding technologies that could preserve its engineered microstructure. This study investigates the microstructural and mechanical properties of butt friction stir welding (FSW) joints of LPBF Scalmalloy® plates under different welding settings. Joint performance was evaluated under quasi-static and cyclic loading conditions. Porosity in Scalmalloy® and welds was assessed using 3D X-ray computed tomography. An aging heat treatment assessed the extent of precipitation hardening in the FSW joints. Results show that metal stirring during FSW notably reduced the intrinsic porosity of Scalmalloy®, decreasing the equivalent pore diameter from about 200 μm to 60 μm in the welded joints. Under quasi-static loading, welded specimens failed at the interface between the thermo-mechanically affected and the stir zones on the advancing side. The aging heat treatment improved the mechanical strength of Scalmalloy® from approximately 400 to 480 MPa, albeit at the expense of ductility (elongation at fracture decreased from 16 to 4%). The higher heat input and stirring developed at a low welding speed reduced lazy S defects but limited the effectiveness of subsequent aging. In fatigue testing, welded joints consistently failed within the aged base material due to the intrinsic porosity of Scalmalloy®.

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Microstructures and mechanical properties of friction stir welded additively manufactured Scalmalloy®

Mirandola,

Novel,

Perini

et al. 2024

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

High strength and fatigue performance achieved for L-PBF processed hybrid particle reinforced Al-Cu-Mg composite

Senol,

Li,

Devulapalli

et al. 2024

Composites Part B: Engineering

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Fatigue behavior of notched and unnotched AM Scalmalloy specimens subjected to different surface treatments

Aguado-Montero,

Vázquez,

Navarro

et al. 2024

International Journal of Fatigue

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Deformation and fatigue behaviour of additively manufactured Scalmalloy® with bimodal microstructure

Cited by 10 publications

References 64 publications

Microstructures and mechanical properties of friction stir welded additively manufactured Scalmalloy®

Microstructures and mechanical properties of friction stir welded additively manufactured Scalmalloy®

High strength and fatigue performance achieved for L-PBF processed hybrid particle reinforced Al-Cu-Mg composite

Fatigue behavior of notched and unnotched AM Scalmalloy specimens subjected to different surface treatments

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