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<p>The AlSi10Mg alloy, widely used in the aerospace, automotive, and biomedical sectors, exhibits excellent mechanical properties when manufactured using Laser Powder Bed Fusion (LPBF). However, this process generates highly heterogeneous microstructures with steep thermal gradients and pronounced grain-orientation anisotropy, making it challenging to predict toughness and failure mechanisms. In this work, series of specimens were produced under various LPBF process parameters and build orientations to accurately assess their influence on mechanical behavior. Quasi-static tensile tests and Charpy impact tests revealed significant variations in strain-hardening behavior, strain-rate sensitivity, and fracture modes. The main contribution of this study lies in the development of a finite element model in LS-DYNA based on the cumulative Johnson–Cook constitutive law, enabling simultaneous control of strain hardening, viscoplasticity, damage evolution, and fracture. An element deletion strategy was implemented to simulate material separation. Despite applying an isotropic simplification to a material that is inherently anisotropic, the model demonstrated convincing predictive capability, accurately reproducing the localization of plastic strains, the kinetics of damage evolution, and the final fracture morphologies observed experimentally. These results show that a well-calibrated isotropic model can, in some cases, reliably predict the dynamic behavior and failure of an additively manufactured anisotropic material. The study thus highlights the importance of numerical simulation for identifying critical LPBF process parameters and optimizing the structural resilience of printed components.</p>

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Experimental and numerical assessment of high-speed Charpy impact on additively manufactured AlSi10Mg alloy

  • 期刊论文

  • 发表日期：

    2026年2月28日

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  • Mohammed EL Alami,
  • Abdellah Laazizi,
  • Igwe Chukwunenye Nnamdi,
  • Iatimad Akhrif,
  • Mostapha El Jai,
  • Itto Ouzouhou

摘要

The AlSi10Mg alloy, widely used in the aerospace, automotive, and biomedical sectors, exhibits excellent mechanical properties when manufactured using Laser Powder Bed Fusion (LPBF). However, this process generates highly heterogeneous microstructures with steep thermal gradients and pronounced grain-orientation anisotropy, making it challenging to predict toughness and failure mechanisms. In this work, series of specimens were produced under various LPBF process parameters and build orientations to accurately assess their influence on mechanical behavior. Quasi-static tensile tests and Charpy impact tests revealed significant variations in strain-hardening behavior, strain-rate sensitivity, and fracture modes. The main contribution of this study lies in the development of a finite element model in LS-DYNA based on the cumulative Johnson–Cook constitutive law, enabling simultaneous control of strain hardening, viscoplasticity, damage evolution, and fracture. An element deletion strategy was implemented to simulate material separation. Despite applying an isotropic simplification to a material that is inherently anisotropic, the model demonstrated convincing predictive capability, accurately reproducing the localization of plastic strains, the kinetics of damage evolution, and the final fracture morphologies observed experimentally. These results show that a well-calibrated isotropic model can, in some cases, reliably predict the dynamic behavior and failure of an additively manufactured anisotropic material. The study thus highlights the importance of numerical simulation for identifying critical LPBF process parameters and optimizing the structural resilience of printed components.