Design of an Innovative Oxide Dispersion Strengthened Al Alloy for Selective Laser Melting to Produce Lighter Components for the Railway Sector

Sorci, R.; Tassa, O.; Colaneri, Alessandro; Astri, Alessandro; Mirabile, Daphne; Iwnicki, Simon; Demir, Ali Gökhan

doi:10.1007/s11665-021-05693-5

Cited by 5 publications

(3 citation statements)

References 28 publications

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“…Mechanical properties of the material depend on the process parameters as well as the machine configuration and the applied heat treatments. The measured properties are comparable to what is reported in the literature [25][26][27][28][29][30].…”

Section: Surface and Materials Propertiessupporting

confidence: 88%

“…Concerning the mechanical properties, AlSi7Mg0.6 can be hardened by an aging treatment. In general practice, a stress-relieving treatment is applied to Al-Si-Mg alloys in order to reduce the thermal stresses generated during the LPBF process [30]. Such treatments generally result in a reduction of the mechanical properties and improve elongation at break compared to the as-built material.…”

Section: Surface and Materials Propertiesmentioning

confidence: 99%

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Laser Powder Bed Fusion of a Topology Optimized and Surface Textured Rudder Bulb with Lightweight and Drag-Reducing Design

Scarpellini

Finazzi

Schito

et al. 2021

JMSE

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This work demonstrates the advantages of using laser powder bed fusion for producing a rudder bulb of a moth class sailing racing boat via laser powder bed fusion (LPBF). The component was designed to reduce weight using an AlSi7Mg0.6 alloy and incorporated a biomimetic surface texture for drag reduction. For the topological optimization, the component was loaded structurally due to foil wing’s lift action as well as from the environment due to hydrodynamic resistance. The aim was to minimize core mass while preserving stiffness and the second to benefit from drag reduction capability in terms of passive surface behavior. The external surface texture is inspired by scales of the European sea bass. Both these features were embedded to the component and produced by LPBF in a single run, with the required resolution. Drag reduction was estimated in the order of for free stream velocity of . The production of the final part resulted in limited geometrical error with respect to scales 3D model, with the desired mechanical properties. A reduction in weight of approximately with respect to original full solid model from 452 to 190 g was achieved thanks to core topology optimization. Sandblasting was adopted as finishing technique since it was able to improve surface quality while preserving fish scale geometries. The feasibility of producing the biomimetic surfaces and the weight reduction were validated with the produced full-sized component.

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Section: Surface and Materials Propertiessupporting

confidence: 88%

Section: Surface and Materials Propertiesmentioning

confidence: 99%

Laser Powder Bed Fusion of a Topology Optimized and Surface Textured Rudder Bulb with Lightweight and Drag-Reducing Design

Scarpellini

Finazzi

Schito

et al. 2021

JMSE

Self Cite

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show abstract

“…Dispersing nanoceramic particles into a metal matrix can enhance many performance aspects of the substrate, including strength, temperature stability, wear, fatigue resistance, and toughness [1][2][3][4][5]. These characteristics have led to the expanded use of nanoceramic particles in various structural, aerospace, automotive, and railway applications [6][7][8].…”

Section: Introductionmentioning

confidence: 99%

An Approach for Material Model Identification of a Composite Coating Using Micro-Indentation and Multi-Scale Simulations

et al. 2022

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While deposited thin film coatings can help enhance surface characteristics such as hardness and friction, their effective incorporation in product design is restricted by the limited understanding of their mechanical behavior. To address this, an approach combining micro-indentation and meso/micro-scale simulations was proposed. In this approach, micro-indentation testing was conducted on both the coating and the substrate. A meso-scale uniaxial compression finite element model was developed to obtain a material model of the coating. This material model was incorporated within an axisymmetric micro-scale model of the coating to simulate the indentation. The proposed approach was applied to a Ti/SiC metal matrix nanocomposite (MMNC) coating, with a 5% weight of SiC nanoparticles deposited over a Ti-6Al-4V substrate using selective laser melting (SLM). Micro-indentation testing was conducted on both the Ti/SiC MMNC coating and the Ti-6Al-4V substrate. The results of the meso-scale finite element indicated that the MMNC coating can be represented using a bi-linear elastic-plastic material model, which was incorporated within an axisymmetric micro-scale model. Comparison of the experimental and micro-scale model results indicated that the proposed approach was effective in capturing the post-indentation behavior of the Ti/SiC MMNC coating. This methodology can also be used for studying the response of composite coatings with different percentages of reinforcements.

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Developing the Additive Manufacturing Chain of AlSi7Mg with Laser Powder Bed Fusion and Tailored Heat Treatments for Railway Spare Parts

Tassa,

Colaneri,

Fransesini

et al. 2023

J. of Materi Eng and Perform

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The use of metal additive manufacturing technologies in railways sector can provide increased flexibility in terms of spare part logistics. Combined with lightweight metals such as Al-alloys, the product performance can also be enhanced in terms of weight reduction, vibration and noise control. The railway sector is more likely to exploit large and bulky parts produced by laser powder bed fusion (LPBF), which should have appropriate mechanical properties. Therefore, the whole production chain should be analyzed considering the heat treatment steps suited for a distributed and resource efficient manufacturing scheme. Accordingly, this work analyzes the additive manufacturing of AlSi7Mg alloy by LPBF and its consecutive heat treatment steps. In particular, the impact of LPBF process productivity, heat treatment type and atmosphere composition were considered to analyze the most appropriate route for the needs of the railways applications. The results show that with an appropriate direct aging treatment in air, mechanical characteristics of the alloy could be improved, despite that the high layer thickness used in LPBF could increase process productivity. The absence of a quenching step was found to be favorable for large parts, while the absence of an inert gas such as Ar in the heat treatment did not generate any reduction in the mechanical properties.

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Design of an Innovative Oxide Dispersion Strengthened Al Alloy for Selective Laser Melting to Produce Lighter Components for the Railway Sector

Cited by 5 publications

References 28 publications

Laser Powder Bed Fusion of a Topology Optimized and Surface Textured Rudder Bulb with Lightweight and Drag-Reducing Design

Laser Powder Bed Fusion of a Topology Optimized and Surface Textured Rudder Bulb with Lightweight and Drag-Reducing Design

An Approach for Material Model Identification of a Composite Coating Using Micro-Indentation and Multi-Scale Simulations

Developing the Additive Manufacturing Chain of AlSi7Mg with Laser Powder Bed Fusion and Tailored Heat Treatments for Railway Spare Parts

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