Relationship between ductility and the porosity of additively manufactured AlSi10Mg

Laursen, Christopher M.; DeJong, Stephanie A.; Dickens, Sara; Exil, Andrea; Susan, Donald Francis; Carroll, Jay

doi:10.1016/j.msea.2020.139922

Cited by 58 publications

(19 citation statements)

References 47 publications

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“…In relation to the mechanical properties, Gong et al [ 103 ] concluded that the tensile strength and fatigue resistance of as-built Ti6Al4V samples are not influenced by 1 vol% of gas pores but are considerably degraded with a volume fraction of 5 vol%. The same conclusions can be rewritten for AlSi10Mg as-built samples [ 14 , 104 ]. In this scenario, the hot isostatic pressing (HIP) HT can be used not only to densify the material but also to reduce the residual stress [ 105 , 106 ].…”

Section: Laser-powder Bed Fusion (L-pbf) Processmentioning

confidence: 75%

Additive Manufacturing of AlSi10Mg and Ti6Al4V Lightweight Alloys via Laser Powder Bed Fusion: A Review of Heat Treatments Effects

Ghio

Cerri

2022

Materials

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Laser powder bed fusion (L-PBF) is an additive manufacturing technology that is gaining increasing interest in aerospace, automotive and biomedical applications due to the possibility of processing lightweight alloys such as AlSi10Mg and Ti6Al4V. Both these alloys have microstructures and mechanical properties that are strictly related to the type of heat treatment applied after the L-PBF process. The present review aimed to summarize the state of the art in terms of the microstructural morphology and consequent mechanical performance of these materials after different heat treatments. While optimization of the post-process heat treatment is key to obtaining excellent mechanical properties, the first requirement is to manufacture high quality and fully dense samples. Therefore, effects induced by the L-PBF process parameters and build platform temperatures were also summarized. In addition, effects induced by stress relief, annealing, solution, artificial and direct aging, hot isostatic pressing, and mixed heat treatments were reviewed for AlSi10Mg and Ti6AlV samples, highlighting variations in microstructure and corrosion resistance and consequent fracture mechanisms.

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Section: Laser-powder Bed Fusion (L-pbf) Processmentioning

confidence: 75%

Additive Manufacturing of AlSi10Mg and Ti6Al4V Lightweight Alloys via Laser Powder Bed Fusion: A Review of Heat Treatments Effects

Ghio

Cerri

2022

Materials

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“…Likewise, with the results shown in Fig. 20, Laursen et al found that porosity (both in terms of fracture surface and bulk material porosities) had a much stronger correlation with elongation than with stiffness or strength for LPBF AlSi10Mg for porosity levels of up to 5% (Archimedes method) [92]. LoF pores being particularly detrimental to vertically built samples were explained by Ronneberg, Davies and Hooper, in their study on LPBF 316L, to be due to how the major axis of LoF pores is oriented relative to the tensile axis as illustrated in Fig.…”

Section: Tensile Propertiesmentioning

confidence: 64%

“…As can be observed, elongation at fracture is generally reported to be far more sensitive to porosity level as compared to strength. The detrimental nature of pores is typically explained through (i) a reduction in the true loadbearing area, (ii) the facilitation of pore coalescence leading to premature failure, (iii) increased stressconcentration points, (iv) acting as initiation sites for micro-cracking, and (iv) providing a preferential path for crack propagation [75,83,[87][88][89][90][91][92][93][94][95]. These issues are frequently reported to be worse for vertically built samples due to the orientation of LoF pores and/or interlayer pores (i.e., pores that are distributed along layer boundaries) [75,90,[96][97][98][99][100][101][102].…”

Section: Tensile Propertiesmentioning

confidence: 99%

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A critical review on the effects of process-induced porosity on the mechanical properties of alloys fabricated by laser powder bed fusion

et al. 2022

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Laser powder bed fusion (LPBF) is an emerging additive manufacturing technique that is currently adopted by a number of industries for its ability to directly fabricate complex near-net-shaped components with minimal material wastage. Two major limitations of LPBF, however, are that the process inherently produces components containing some amount of porosity and that fabricated components tend to suffer from poor repeatability. While recent advances have allowed the porosity level to be reduced to a minimum, consistent porosity-free fabrication remains elusive. Therefore, it is important to understand how porosity affects mechanical properties in alloys fabricated this way in order to inform the safe design and application of components. To this aim, this article will review recent literature on the effects of porosity on tensile properties, fatigue life, impact and fracture toughness, creep response, and wear behavior. As the number of alloys that can be fabricated by this technology continues to grow, this overview will mainly focus on four alloys that are commonly fabricated by LPBF—Ti-6Al-4 V, Inconel 718, AISI 316L, and AlSi10Mg.

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“…Regarding ductility, in a rather brittle alloy like AM AlSi10Mg, pores are expected to serve as failure initiating features, thereby seeding damage nucleation and reducing overall ductility; indeed, multiple empirical models have shown a correlation between increasing porosity and reduced ductility of AM AlSi10Mg. 26 Similar correlations between porosity and mechanical properties are exhibited in cast aluminum. 25,27,28 Porosity, and other heterogeneities formed by LPBF typically lead to more variability in mechanical performance compared with wrought material.…”

Section: Introductionmentioning

confidence: 61%

High-Throughput Statistical Interrogation of Mechanical Properties with Build Plate Location and Powder Reuse in AlSi10Mg

Carroll

Exil

DeJong

et al. 2021

JOM

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Additive manufacturing (AM) allows agile, rapid manufacturing of geometrically complex components that would otherwise be impossible through traditional manufacturing methods. With this maturing manufacturing technology comes the need to adopt testing methods that are commensurate with the speed of additive manufacturing and take advantage of its geometric flexibility. High-throughput tensile testing (HTT) is a technique that allows a large number of tensile bars to be tested in a short amount of time. In the present study, HTT is used to evaluate AM AlSi10Mg produced using powder bed fusion with a Renishaw AM250 machine. Three parameters were varied in this study: (1) powder reuse history, (2) location on the build plate, and (3) size of the tensile specimen. For all parameter combinations, at least 22 specimens were tested; in several cases, over 40 were tested. This large dataset, consisting of over 500 tensile tests, permits Weibull statistical analysis and provides sufficient fidelity to isolate subtle trends that would have likely been missed in smaller, traditional datasets. The observed trends are rationalized in terms of the role of porosity and surface crust on mechanical response.

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Relationship between ductility and the porosity of additively manufactured AlSi10Mg

Cited by 58 publications

References 47 publications

Additive Manufacturing of AlSi10Mg and Ti6Al4V Lightweight Alloys via Laser Powder Bed Fusion: A Review of Heat Treatments Effects

Additive Manufacturing of AlSi10Mg and Ti6Al4V Lightweight Alloys via Laser Powder Bed Fusion: A Review of Heat Treatments Effects

A critical review on the effects of process-induced porosity on the mechanical properties of alloys fabricated by laser powder bed fusion

High-Throughput Statistical Interrogation of Mechanical Properties with Build Plate Location and Powder Reuse in AlSi10Mg

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