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<p>Aluminum alloys and additive manufacturing are currently being developed for structural applications. This study uses powder bed fusion with laser beam technology to investigate the influence of build orientation and heat treatment on fatigue crack growth and fracture toughness in components made of AlSi10Mg. The research was conducted using a specific experimental setup and procedures. The specimens were produced in two build orientations (45° and 90°) and underwent two heat treatments: direct aging at 170&#xa0;°C (A170) for 2&#xa0;h and stress relief at 300&#xa0;°C for 2&#xa0;h (SR300). SR300 specimens exhibited lower values of the <i>m</i> parameter in the Paris’ equation, with values of 2.9 for both the 90° and 45° build orientations. On the other hand, 45° built specimens subjected to A170 showed an <i>m</i> value of 3.6, while 90° orientation presented an <i>m</i> value of 4.0. The fracture toughness tests indicated that the SR300 resulted in higher toughness than A170. A 45° build orientation also resulted in higher toughness compared to a 90° orientation. Due to the low thickness (~ 3&#xa0;mm) of the fracture toughness, the results of the J-integral (J) delivered important insights into new applications in thin walls and lattice structures. Still, due to the ASTM 1820 standard focused on fracture toughness tests, the results do not qualify the thickness criteria (J<sub>Q</sub>) to provide values that are considered critical in conventional tests of thick samples. The highest J<sub>Q</sub> was 14.3&#xa0;kJ<i>/m</i><sup><i>2</i></sup> for the SR300 with a 45° build orientation. The lowest J<sub>Q</sub> was 3.5&#xa0;kJ<i>/m</i><sup><i>2</i></sup> for the A170 with a 90° build orientation.</p>

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Fatigue crack propagation and fracture toughness of AlSi10Mg alloy processed by powder bed fusion: effects of post-processing heat treatments

  • 期刊论文

  • 发表日期：

    2025年6月18日

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  • Diego Valim,
  • Julian Avila,
  • Diego F. B. Sarzosa,
  • Cristiano Justiniano,
  • André Jardini,
  • Éder S. N. Lopes

摘要

Aluminum alloys and additive manufacturing are currently being developed for structural applications. This study uses powder bed fusion with laser beam technology to investigate the influence of build orientation and heat treatment on fatigue crack growth and fracture toughness in components made of AlSi10Mg. The research was conducted using a specific experimental setup and procedures. The specimens were produced in two build orientations (45° and 90°) and underwent two heat treatments: direct aging at 170 °C (A170) for 2 h and stress relief at 300 °C for 2 h (SR300). SR300 specimens exhibited lower values of the m parameter in the Paris’ equation, with values of 2.9 for both the 90° and 45° build orientations. On the other hand, 45° built specimens subjected to A170 showed an m value of 3.6, while 90° orientation presented an m value of 4.0. The fracture toughness tests indicated that the SR300 resulted in higher toughness than A170. A 45° build orientation also resulted in higher toughness compared to a 90° orientation. Due to the low thickness (~ 3 mm) of the fracture toughness, the results of the J-integral (J) delivered important insights into new applications in thin walls and lattice structures. Still, due to the ASTM 1820 standard focused on fracture toughness tests, the results do not qualify the thickness criteria (JQ) to provide values that are considered critical in conventional tests of thick samples. The highest JQ was 14.3 kJ/m2 for the SR300 with a 45° build orientation. The lowest JQ was 3.5 kJ/m2 for the A170 with a 90° build orientation.