Abstract
This work concerns the fatigue resistance of a AlSi10Mg material produced by additive manufacturing, and more precisely the competition between as built manufacturing surface and as-machined surface on the fatigue resistance. Samples were built by a powder-bed process with an EOS-M280 machine using standard in two configurations (0° and 90°) in order to evaluate the impact of building direction on fatigue life. The impact of as-built surface on fatigue behavior is quantified for each specimen configuration. A T6 heat treatment is performed on samples in order to evaluate the impact of microstructure on fatigue behavior. For each configurations, the S-N curves is determined in as-built and T6 materials with a load ratio R= -1. The fracture surfaces are carefully analyzed in order to determine the critical defect size for each sample. A Kitagawa type diagram representing the fatigue limit as a function of the defect size is derived from these measurements. All the results were compared to those obtained in asmachined samples.
Highlights
Additive Layer Manufacturing (ALM) is a breakthrough process compared to conventional processes such as casting, in particular to produce parts with a complex shape
It has been observed that melt-pools, dendritic structure and grains are strongly anisotropic in shape depending on the building direction
In order to plot a Kitagawa-type diagram, the fatigue limit is determined for each specimen after failure according to the following method:
Summary
Additive Layer Manufacturing (ALM) is a breakthrough process compared to conventional processes such as casting, in particular to produce parts with a complex shape. According to Domfang et al [4], the microstructure in the bulk of the non-heat treated ALM AlSi10Mg material can be described using five parameters: (i) defect population, (ii) melt-pools, (iii) dendritic structure, (iv) precipitation structure and (v) grains. In addition the melt-pools and dendrites disappear after a T6 heat treatment [4]. The surfaces of near net-shape pieces are characterized by a high roughness that could impact the fatigue behavior. Since most of the ALM parts are partially machined, the aim of this study is to compare the fatigue behavior of as-machined samples to samples with a near net shape cross section called as-built samples
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