Friction stir processing of AlSi10Mg parts produced by selective laser melting

Maamoun, Ahmed; Veldhuis, Stephen C.; Elbestawi, M.A.

doi:10.1016/j.jmatprotec.2018.08.030

Cited by 56 publications

(31 citation statements)

References 29 publications

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“…The microhardness is 115 to 118 HV along the range of the SLM parameters, which confirms better homogeneity along the XY direction, Figure 3. This trend agrees with literature studies [18,20,22]. The reduction in laser power and greater hatch spacing improves microhardness along the XY plane as shown in Figure 11(a, c).…”

Section: Mechanical Propertiessupporting

confidence: 92%

“…Application of energy densities higher than 50J/mm 3 caused no significant difference in the microstructure. However, the XRD measurements were performed for a more accurate analysis of crystal size change and solubility percentage of the Si inside the Al matrix [22,23]. The zoom-in views of Figure 3(a, b, c) show more details about the evolution of the Al matrix grain inside the melt pool profile, which increases along with the energy density applied.…”

Section: Microstructurementioning

confidence: 99%

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On the Effect of Selective Laser Melting Process Parameters on the Microstructure and Mechanical Properties of Al Alloys

Maamoun¹,

Xue²,

Elbestawi³

et al. 2018

Preprint

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Additive manufacturing (AM) offers customization of microstructure and mechanical properties of fabricated components according to the material selected, and process parameters applied. Selective laser melting (SLM) is the commonly used technique for processing high strength aluminum alloys. Selection of SLM process parameters could control the microstructure of parts and their mechanical properties. However, the process parameters limit and defects obtained inside the as-built parts present obstacles to customized part production. This study investigates the influence of SLM process parameters on the quality of as-built Al6061 and AlSi10Mg parts according to the mutual connection between the microstructure characteristics and mechanical properties. The microstructure of both materials was characterized for different parts processed over a wide range of SLM process parameters. The optimized SLM parameters were investigated to eliminate the internal microstructure defects. The behaviour of mechanical properties of parts was presented through regression models generated from the design of experiment (DOE) analysis for the results of hardness, ultimate tensile strength, and yield strength. A comparison between the results obtained and that reported in the literature is presented to illustrate the influence of process parameters, build environment, and powder characteristics on the quality of parts produced. The results obtained from this study could help to customize the part’s quality by satisfying their design requirements in addition to reducing the as-built defects which in turn reduce the amount of the post-processing needed.

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Section: Mechanical Propertiessupporting

confidence: 92%

Section: Microstructurementioning

confidence: 99%

On the Effect of Selective Laser Melting Process Parameters on the Microstructure and Mechanical Properties of Al Alloys

Maamoun¹,

Xue²,

Elbestawi³

et al. 2018

Preprint

Self Cite

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“…However, the particles added in this way are easy to slip and splash during the FSP process; hence, there is an inhomogeneous distribution of the strengthening phases and a loss of material. Based on this method, pre-fabricated surface composites can be fabricated by cold spraying [44,45] or laser melting [46] with further processing of the coating via FSP. This can improve the microstructure and the distribution of the reinforced particles to obtain surface composites with better properties.…”

Section: Methods Of Adding Reinforced Particlesmentioning

confidence: 99%

“…Zhu et al [75] Al AlSi10Mg selective laser melting FSP could be used to improve the microstructure and reduce porosity. Maamoun et al [46] Hosseini et al [37] used an Al5083 alloy as the matrix material, CeO 2 and carbon nanotubes (CNTs) as the strengthening phase, and obtained the surface hybrid composites via multi-pass FSP. Many CeO 2 /Al5083, CNTs/Al5083, and CeO 2 /CNTs/Al5083 composite modes were evaluated by changing the volume ratio of CeO 2 and CNTs.…”

Section: Mahmoud Et Al [70]mentioning

confidence: 99%

Research Status and Prospect of Friction Stir Processing Technology

Liu

Zhao

2019

Coatings

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Friction stir processing (FSP) is a novel solid-phase processing technique that is derived from friction stir welding (FSW). The microstructure of the base metal can be modified with the friction heat and stir function during processing. It can be used to fabricate surface composites and in situ composites by adding reinforced particles into the metal matrix via FSP. Friction stir processing can significantly improve the hardness, wear resistance, ductility, etc., while preventing defects caused by material melting. It is an ideal material processing technology and has good prospects in the field of superplastic materials and for the preparation of metal matrix composites. This paper reviews research developments into the principle, process, and applications of FSP technology as well as its future research directions and development prospects.

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“…Up to now, there is no clear explanation for such a fluctuation. As most reported residual stress measurements using XRD were performed on as-built SLM-produced samples without considering the effect of surface roughness [14,22,[28][29][30][31][32], some researchers consider the pretreatment prior to XRD measurements is necessary because the high surface roughness of the as-built samples can lead to inaccurate measurement of residual stresses [5,18]. For example, P. Mercelis et al [5] proposed electrical discharge machining (EDM) and chemical etching before XRD measurements to obtain the actual residual stresses for SLM-produced 316L stainless steel samples.…”

Section: Introductionmentioning

confidence: 99%

Strategy of Residual Stress Determination on Selective Laser Melted Al Alloy Using XRD

Chen

Sun

Li³

et al. 2020

Materials

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Selective laser melting (SLM) is known to generate large and anisotropic residual stresses in the samples. Accurate measurement of residual stresses on SLM-produced samples is essential for understanding the residual stress build-up mechanism during SLM, while a dramatic fluctuation can be observed in the residual stress values reported in the literature. On the basis of studying the influence of surface roughness on residual stress measured using X-ray diffraction (XRD), we propose a procedure coupling XRD technique with pretreatment consisting of mechanical polishing and chemical etching. The results highlight that residual stresses measured using XRD on as-built SLM-produced samples with high surface roughness are significantly lower than those measured on samples with finished surface, which is due to the stress relaxation on the spiked surface of as-built samples. Surface distribution of residual stresses and the effect of scanning strategy were systematically investigated for SLM-produced AlSi10Mg samples. Microstructural morphology was observed at the interface between sample and building platform and was linked to the surface distribution of residual stresses. This procedure can help us accurately measure the residual stresses in SLM-produced samples and thus better understand its build-up mechanism during the SLM process.

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Friction stir processing of AlSi10Mg parts produced by selective laser melting

Cited by 56 publications

References 29 publications

On the Effect of Selective Laser Melting Process Parameters on the Microstructure and Mechanical Properties of Al Alloys

On the Effect of Selective Laser Melting Process Parameters on the Microstructure and Mechanical Properties of Al Alloys

Research Status and Prospect of Friction Stir Processing Technology

Strategy of Residual Stress Determination on Selective Laser Melted Al Alloy Using XRD

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