Selective laser melting of AlSi10Mg alloy: Process optimisation and mechanical properties development

Read, Noriko; Wang, Wei; Essa, Khamis; Attallah, Moataz M.

doi:10.1016/j.matdes.2014.09.044

Cited by 969 publications

(469 citation statements)

References 17 publications

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“…• Al-Si alloys: Due to their attractive combination of low weight, high heat conductivity and mechanical properties, Al-Si alloys (AlSi10Mg [151][152][153][154][155][156][157] and Al-12Si [158,159]) have wide applications in aerospace, automotive industries as heat exchangers. AlSi10Mg and Al-12Si are hypoeutectic alloys whose mechanical properties are largely dependant on the morphology of eutectic silicon.…”

Section: Materials Manufactured With Slmmentioning

confidence: 99%

Additively Manufactured Inconel 718 : Microstructures and Mechanical Properties

Deng

2018

Linköping Studies in Science and Technology. Licentiate Thesis

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Linköping 2018Cover image: A fracture surface of EBM IN718 after tensile test at room temperature.During the course of research underlying this thesis, Dunyong Deng was enrolled in Agora Materiae, a multidiciplinary doctoral program at Linköping University, Sweden. Printed by LiU-Tryck 2018 © Dunyong Deng AbstractAdditive manufacturing (AM), also known as 3D printing, has gained significant interest in aerospace, energy, automotive and medical industries due to its capabilities of manufacturing components that are either prohibitively costly or impossible to manufacture by conventional processes. Among the various additive manufacturing processes for metallic components, electron beam melting (EBM) and selective laser melting (SLM) are two of the most widely used powder bed based processes, and have shown great potential for manufacturing high-end critical components, such as turbine blades and customized medical implants. The futures of the EBM and SLM are doubtlessly promising, but to fully realize their potentials there are still many challenges to overcome.Inconel 718 (IN718) is a nickel-base superalloy and has impressive combination of good mechanical properties and low cost. Though IN718 is being mostly used as a turbine disk material now, the initial introduction of IN718 was to overcome the poor weldability of superalloys in 1960s, since sluggish precipitation of strengthening phases γ ′ /γ ′′ enables good resistance to strain-age cracking during welding or post weld heat treatment. Given the similarity between AM and welding processes, IN718 has been widely applied to the metallic AM field to facilitate the understandings of process-microstructure-property relationships.The work presented in this licentiate thesis aims to better understand microstructures and mechanical properties EBM and SLM IN718, which have not been systematically investigated. Microstructures of EBM and SLM IN718 have been characterized with scanning electron microscopy (SEM), transmission electron microscopy (TEM) and correlated with the process conditions. Monotonic mechanical properties (e.g., Vickers microhardness and tensile properties) have also been measured and rationalized with regards to the microstructure evolutions before and after heat treatments.For EBM IN718, the results show the microstructure is not homogeneous but dependant on the location in the components, and the anisotropic mechanical properties are probably attributed to alignment of porosities rather than texture.iii Post heat treatment can slightly increase the mechanical strength compared to the as-manufactured condition but does not alter the anisotropy. SLM IN718 shows significantly different microstructure and mechanical properties to EBM IN718. The as-manufactured SLM IN718 has very fine dendritic microstructure and Laves phases in the interdendrites, and is "work-hardened" by the residual strains and dislocations present in the material. Mechanical properties are different between horizontally and vertically built samples, and heat treatment can m...

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Section: Materials Manufactured With Slmmentioning

confidence: 99%

Additively Manufactured Inconel 718 : Microstructures and Mechanical Properties

Deng

2018

Linköping Studies in Science and Technology. Licentiate Thesis

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“…Compared with the powder induced porosity, the process induced one has received more research attention since it can be eliminated by tuning the process parameters properly. The high viscosity [31] and the solubility decrease [32] of molten powder materials, improper laser scanning strategies [21], laser power, speed [33], spot diameter, powder layer thickness, preheat temperature [23], hatching spacing [24] would detrimentally cause porosity since low energy input would decrease the area of melt pool and lead to incomplete consolidation [25]. The porosity will continuously have influence on surface roughness and finally geometrical accuracy [20,31,[34][35][36].…”

Section: Additive Manufacturingmentioning

confidence: 99%

Integration of physically-based and data-driven approaches for thermal field prediction in additive manufacturing

Jin

2018

Materials & Design

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A quantitative understanding of thermal field evolution is vital for quality control in additive manufacturing (AM). Because of the unknown material parameters, high computational costs, and imperfect understanding of the underlying science, physically-based approaches alone are insufficient for component-scale thermal field prediction. Here, I present a new framework that integrates physically-based and data-driven approaches with quasi in situ thermal imaging to address this problem. The framework consists of (i) thermal modeling using 3D finite element analysis (FEA), (ii) surrogate modeling using functional Gaussian process, and (iii) Bayesian calibration using the thermal imaging data. Based on heat transfer laws, I first investigate the transient thermal behavior during AM using 3D FEA. A functional Gaussian process-based surrogate model is then constructed to reduce the computational costs from the high-fidelity, physically-based model. I finally employ a Bayesian calibration method, which incorporates the surrogate model and thermal measurements, to enable layer-to-layer thermal field prediction across the whole component. A case study on fused deposition modeling is conducted for components with 7 to 16 layers. The cross-validation results show that the proposed framework allows for accurate and fast thermal field prediction for components with different process settings and geometric designs. Integration of Physically-based and Data-driven Approaches for Thermal Field Prediction in Additive ManufacturingJingran Li GENERAL AUDIENCE ABSTRACT This paper aims to achieve the layer to layer temperature monitoring and consequently predict the temperature distribution for any new freeform geometry. An engineering statistical synergistic model is proposed to integrate the pure statistical methods and finite element modeling (FEM), which is physically meaningful as well as accurate for temperature prediction. Besides, this proposed synergistic model contains geometry information, which can be applied to any freeform geometry. This paper serves to enable a holistic cyber physical systems-based approach for the additive manufacturing (AM) not only restricted in fused deposition modeling (FDM) process but also can be extended to powder-based process like laser engineered net shaping (LENS) and selective laser sintering (SLS). This paper as well as the scheduled future works will make it affordable for customized AM including customized geometries and materials, which will greatly accelerate the transition from rapid prototyping to rapid manufacturing. This article demonstrates a first evaluation of engineering statistical synergistic model in AM technology, which gives a perspective on future researches about online quality monitoring and control of AM based data fusion principles. iv ACKNOWLEDGEMENTS

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“…observed the same trend using a different material, namely a A1Si10Mg alloy. They concluded that the porosity increase above a critical energy density was caused by vapourisation [30].…”

Section: Density and Porosity Measurementsmentioning

confidence: 99%

“…al. reported the major influence on the SLS build arising from the interaction between laser power, scan speed and scan spacing [30]. From the literature studies, it was concluded that laser power and scan speed are the crucial parameters in determining the porosity of the fabricated parts.…”

Section: Introductionmentioning

confidence: 99%

Electrical conductivity and porosity in stainless steel 316L scaffolds for electrochemical devices fabricated using selective laser sintering

Ibrahim

Brandon

2016

Materials & Design

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Battery electrode microstructures must be porous, to provide a large active surface area to facilitate fast charge transfer kinetics. In this work, we describe how a novel porous electrode scaffold, made from stainless steel 316L powder can be fabricated using selective laser sintering by proper selection of process parameters. Porosity, electrical conductivity and optical microscopy measurements were used to investigate the properties of fabricated samples. Our results show that a laser energy density between 1.50-2.00 J/mm 2 leads to a partial laser sintering mechanism where the powder particles are partially fused together, resulting in the fabrication of electrode scaffolds with 10% or higher porosity. The sample fabricated using 2.00 J/mm 2 energy density (60W -1200 mm/s) exhibited a good electrical conductivity of 1.80 x 10 6 S/m with 15.61% of porosity. Moreover, we have observed the porosity changes across height for the sample fabricated at 60W and 600 mm/s, 5.70% from base and increasing to 7.12% and 9.89% for each 2.5 mm height toward the top surface offering graded properties ideal for electrochemical devices, due to the changing thermal boundary conditions. These highly porous electrode scaffolds can be used as an electrode in electrochemical devices, potentially improving energy density and life cycle.

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Selective laser melting of AlSi10Mg alloy: Process optimisation and mechanical properties development

Cited by 969 publications

References 17 publications

Additively Manufactured Inconel 718 : Microstructures and Mechanical Properties

Additively Manufactured Inconel 718 : Microstructures and Mechanical Properties

Integration of physically-based and data-driven approaches for thermal field prediction in additive manufacturing

Electrical conductivity and porosity in stainless steel 316L scaffolds for electrochemical devices fabricated using selective laser sintering

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