Surface residual stress analysis of additive manufactured AlSi10Mg alloys

Kim, InYeong; Park, Sang Cheol; Kim, Young Il; Kim, Dae-Kyeom; Lee, Kee‐Ahn; Oh, Soong Ju; Liu, Bin

doi:10.1016/j.jallcom.2023.169315

Cited by 14 publications

(5 citation statements)

References 46 publications

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“…[ 42 ] This relationship describes the change in diffraction angle (2 θ ) as a function of the sine squared (sin 2 ψ) of the incident angle of the X‐rays. [ 43 ]…”

Section: Resultsmentioning

confidence: 99%

“…The utilization of L‐PBF methodology for the production of AlSi10Mg yields a hierarchical microstructure distinguished by the simultaneous presence of cell and grain structures, in addition to nanoscale Si precipitates and densely populated dislocation networks. [ 43 ] The confluence of these structural attributes effectively enhances the mechanical robustness of the alloy through the obstruction of dislocation mobility. The interaction between the network of dislocations and the eutectic Si walls, as depicted in Figure 6, acts as a hindrance to dislocation motion during deformation.…”

Section: Resultsmentioning

confidence: 99%

“…[42] This relationship describes the change in diffraction angle (2θ) as a function of the sine squared (sin 2 ψ) of the incident angle of the X-rays. [43] It is conceivable to state that there exists a correlation between the utilization of lower LP settings and the occurrence of elevated levels of residual stress in the material. The correlation arises due to the consistent maintenance of all other process parameters, resulting in a decrease in laser line energy.…”

Section: Phase Composition Residual Stress Analysis and Nanohardnessmentioning

confidence: 99%

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Investigating the Microstructural and Mechanical Characteristics of Laser Additive‐Manufactured AlSi10Mg Specimens Through Experimental and Phase‐Field Modeling Approaches

Panda,

Sahoo,

Kumar

et al. 2024

Adv Eng Mater

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Metal‐based additive manufacturing can make complicated parts that are complex or expensive to cast and process. Rapid cooling rates increase L‐PBF’s mechanical properties during manufacturing. The objective of this study is to examine the impact of process parameters in the L‐PBF technique on the characteristics of microstructure and mechanical properties, specifically, on the nano‐hardness influenced by Si segregation. The microstructures of the produced specimens were examined using FESEM and the analysis identified the existence of bimodal equiaxed α‐Al grains, accompanied by Si phases located within their grain boundaries. In addition, the solidified sample exhibited the segregation of secondary precipitates, particularly , which resulted in enhanced mechanical properties. Both cellular walls and Si precipitates impede the motion and generation of dislocations, thereby influencing the overall behavior of dislocations. The examination of segregation at the top layer was conducted in a comprehensive manner, subsequently employing EDS for analysis. The presence of , , and other phases in all samples was confirmed through XRD. The as‐built samples’ residual stress under different process conditions was also investigated. In addition, a comparison was made between the obtained microstructure and a phase field model that was developed in order to forecast the evolution of the microstructure.This article is protected by copyright. All rights reserved.

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“…[ 42 ] This relationship describes the change in diffraction angle (2 θ ) as a function of the sine squared (sin 2 ψ) of the incident angle of the X‐rays. [ 43 ]…”

Section: Resultsmentioning

confidence: 99%

Section: Resultsmentioning

confidence: 99%

Section: Phase Composition Residual Stress Analysis and Nanohardnessmentioning

confidence: 99%

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Investigating the Microstructural and Mechanical Characteristics of Laser Additive‐Manufactured AlSi10Mg Specimens Through Experimental and Phase‐Field Modeling Approaches

Panda,

Sahoo,

Kumar

et al. 2024

Adv Eng Mater

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“…The microstructural evolution of the samples at different post-heating conditions is presented in Figure 18 [81]. Yeong Kim et al [82] investigated the effect of heat treatment on the residual stress present in aluminum alloy fabricated using the PBF process. The fabricated samples were heat treated in a vacuum at a temperature of 480 °C or 550 °C for 6 h, then allowed to cool down naturally in a furnace.…”

Section: Heat Treatmentmentioning

confidence: 99%

“…The fabricated samples were heat treated in a vacuum at a temperature of 480 °C or 550 °C for 6 h, then allowed to cool down naturally in a furnace. The heat treatment process changed the tensile residual stress Yeong Kim et al [82] investigated the effect of heat treatment on the residual stress present in aluminum alloy fabricated using the PBF process. The fabricated samples were heat treated in a vacuum at a temperature of 480 • C or 550 • C for 6 h, then allowed to cool down naturally in a furnace.…”

Section: Heat Treatmentmentioning

confidence: 99%

A Review of the Residual Stress Generation in Metal Additive Manufacturing: Analysis of Cause, Measurement, Effects, and Prevention

Bastola,

Jahan,

Rangasamy

et al. 2023

Micromachines

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Metal additive manufacturing (AM) is capable of producing complex parts, using a wide range of functional metals that are otherwise very difficult to make and involve multiple manufacturing processes. However, because of the involvement of thermal energy in the fabrication of metallic AM parts, residual stress remains one of the major concerns in metal AM. This residual stress has negative effects on part quality, dimensional accuracy, and part performance. This study aims to carry out a comprehensive review and analysis of different aspects of residual stress, including the causes and mechanisms behind the generation of residual stress during metal AM, the state-of-the-art measurement techniques for measuring residual stress, various factors influencing residual stress, its effect on part quality and performance, and ways of minimizing or overcoming residual stress in metal AM parts. Residual stress formation mechanisms vary, based on the layer-by-layer deposition mechanism of the 3D printing process. For example, the residual stress formation for wire-arc additive manufacturing is different from that of selective laser sintering, direct energy deposition, and powder bed fusion processes. Residual stress formation mechanisms also vary based on the scale (i.e., macro, micro, etc.) at which the printing is performed. In addition, there are correlations between printing parameters and the formation of residual stress. For example, the printing direction, layer thickness, internal structure, etc., influence both the formation mechanism and quantitative values of residual stress. The major effect residual stress has on the quality of a printed part is in the distortion of the part. In addition, the dimensional accuracy, surface finish, and fatigue performance of printed parts are influenced by residual stress. This review paper provides a qualitative and quantitative analysis of the formation, distribution, and evolution of residual stress for different metal AM processes. This paper also discusses and analyzes both in situ and ex situ measurement techniques for measuring residual stress. Microstructural evolution and its effect on the formation of residual stress are analyzed. Various pre- and post-processing techniques used to countermeasure residual stress are discussed in detail. Finally, this study aims to present both a qualitative and quantitative analysis of the existing data and techniques in the literature related to residual stress, as well as to provide a critical analysis and guidelines for future research directions, to prevent or overcome residual stress formation in metal AM processes.

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On the Damping Performance and Mechanical Response of Additive-Manufactured and Thermo-Mechanical Processed AlSiMg Alloy

Isil,

Radi,

Yapici

2024

Met. Mater. Int.

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Recent advancements in additive manufacturing (AM) fuel efforts for expanding the design envelopes for components obtained via this technology through continuous improvement in mechanical behavior. Damping properties can also be altered depending on the microstructure evolved during AM. Therefore, achieving enhanced monotonic mechanical response with better damping properties is highly sought-after. In this respect, thermo-mechanical processing via severe plastic deformation (SPD) and artificial aging is imparted on the additive-manufactured samples with the target of grain refinement and densification to further improve mechanical and damping properties. Employing microstructural characterizations and mechanical experiments, a multi-scale exploration is carried out to develop a relation between the evolved microstructure and the resulting behavior. It is concluded that introducing a refined microstructure decorated with well-distributed (Mg,Si)-rich phase and favorable dislocation substructure in AlSi10Mg positively affects the resulting mechanical behavior. Moreover, it is shown that artificial aging can be employed to improve the damping characteristics of severely deformed additive-manufactured AlSi10Mg alloy. Graphical Abstract

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Surface residual stress analysis of additive manufactured AlSi10Mg alloys

Cited by 14 publications

References 46 publications

Investigating the Microstructural and Mechanical Characteristics of Laser Additive‐Manufactured AlSi10Mg Specimens Through Experimental and Phase‐Field Modeling Approaches

Investigating the Microstructural and Mechanical Characteristics of Laser Additive‐Manufactured AlSi10Mg Specimens Through Experimental and Phase‐Field Modeling Approaches

A Review of the Residual Stress Generation in Metal Additive Manufacturing: Analysis of Cause, Measurement, Effects, and Prevention

On the Damping Performance and Mechanical Response of Additive-Manufactured and Thermo-Mechanical Processed AlSiMg Alloy

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