Effect of process parameters and post-treatments on the mechanical static and fatigue properties of SLM AlSi10Mg alloy

Marteleur, Matthieu;van der Rest, Camille;Couturiaux, Gaelle;Godet, Stéphane;Simar, Aude;et.al.
(2019) First European Conference on Structural Integrity of Additively Manufactured Materials (ESIAM19) — Location: Trondheim, Norway (9.September.2019)

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Metal additive manufacturing and in particular selective laser melting (SLM) is a very promising production method. SLM alloy AlSi10Mg, as a common lightweight structural alloy, has already drawn the attention of the aerospace industry due to its good strength-to-weight ratio. Its high strength (resulting from the very fine Si network formed during rapid cooling) compared to cast alloys of the same composition is clearly an asset of the technology. However, when aiming at reaching the requirements of highly demanding structural applications, the fatigue life of SLM AlSi10Mg does not reach the performances met by wrought aluminium alloys. The poor fatigue resistance in the as-built condition is attributed to residual stresses, high surface roughness and process-induced porosities favouring early fatigue crack initiation. In the frame of an industrial case study of aircraft conventional part replacement by a 3D printed one, a characterisation campaign has been led about the microstructure and the mechanical behaviour of SLM AlSi10Mg alloy. Cubic and cylindrical specimens have been fabricated and various process parameters (layer thickness, orientation,…) and post-treatments (stress relief, shot-peening, hot isostatic pressing,…) have been studied. Both static mechanical tests and fatigue tests were performed and coupled with an in-depth characterisation of the corresponding microstructures. The effect of the various post-treatments on the improvement of fatigue life is finally discussed.
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Marteleur, M., van der Rest, C., Couturiaux, G., Godet, S., Jacques, P., & Simar, A. (2019). Effect of process parameters and post-treatments on the mechanical static and fatigue properties of SLM AlSi10Mg alloy. First European Conference on Structural Integrity of Additively Manufactured Materials (ESIAM19), Trondheim, Norway. https://hdl.handle.net/2078.5/23870