Fatigue life improvement of 7075 aluminium alloy produced by laser powder bed fusion (L-PBF)

Nothomb, Nicolas;Rosar Longin, Julien;Rodriguez-Barber, Ignacio;Pérez Prado, Maria Teresa;Simar, Aude;et.al.
(2023) ESIAM23: 3rd European Conference on the Structural Integrity of Additively Manufactured Materials — Location: Porto, Portugal (4.September.2023)

Files

AbstractNicolasNothombESIAM23.pdf
  • Open Access
  • Adobe PDF
  • 134.33 KB
Download

Details

Authors
Show more
Abstract
One of the main drawbacks of Laser Powder Bed Fusion (L-PBF) is the limited material palette currently available and the often poor fatigue performance of the resulting parts. Currently, the only high-performance aluminium alloy manufacturable by L-PBF and adapted for the aerospace industry is Scalmalloy®. Moreover, this alloy uses Scandium as an alloying element which should be avoided due to its very high price. The production of parts using more conventional 7xxx aluminium alloys with the L-PBF technology is not yet fully controlled. In this study, static mechanical properties as well as fatigue performances of an Al7075 modified to avoid hot cracking manufactured by L-PBF will be analysed. First, ZrH2 addition to the Al7075 powder allows obtaining nearly fully dense parts without cracking: 99.9% relative density computed using X-Ray tomography. Afterwards, an optimised heat treatment is applied to this alloy to enhance its mechanical performances and reach a yield strength of 510MPa by controlling Cu, Mg, Zn and Zr precipitation. Finally, as fatigue performances of L-PBF alloys are usually poor, friction stir processing was applied as a post-treatment to suppress the main part of the porosities and improve fatigue performances. Indeed, friction stir processing has been proven as a very successful post-processing method to increase the fatigue life of AlSi10Mg by a factor of 100.
Affiliations

Citations

  • APA
  • Chicago
  • FWB

Nothomb, N., Rosar Longin, J., Rodriguez-Barber, I., Pérez Prado, M. T., Avettand-Fénoël, M.-N., & Simar, A. (2023). Fatigue life improvement of 7075 aluminium alloy produced by laser powder bed fusion (L-PBF). ESIAM23: 3rd European Conference on the Structural Integrity of Additively Manufactured Materials, Porto, Portugal. https://hdl.handle.net/2078.5/267593