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High-cycle fatigue properties of curved-surface AlSi10Mg parts fabricated by powder bed fusion additive manufacturing

Yue Zhou (Department of Systems Science and Industrial Engineering, State University of New York at Binghamton, Binghamton, New York, USA)
El Mehdi Abbara (Department of Systems Science and Industrial Engineering, State University of New York at Binghamton, Binghamton, New York, USA and Center for Advanced Microelectronics Manufacturing, State University of New York at Binghamton, Binghamton, New York, USA)
Dayue Jiang (Department of Systems Science and Industrial Engineering, State University of New York at Binghamton, Binghamton, New York, USA)
Arad Azizi (Department of Mechanical Engineering, State University of New York at Binghamton, Binghamton, New York, USA)
Mark D. Poliks (Department of Systems Science and Industrial Engineering, State University of New York at Binghamton, Binghamton, New York, USA and Center for Advanced Microelectronics Manufacturing, State University of New York at Binghamton, Binghamton, New York, USA)
Fuda Ning (Department of Systems Science and Industrial Engineering, State University of New York at Binghamton, Binghamton, New York, USA)

Rapid Prototyping Journal

ISSN: 1355-2546

Article publication date: 10 February 2022

Issue publication date: 29 June 2022

723

Abstract

Purpose

This study aims to uncover the multiscale relations among geometry, surface finish, microstructure and fatigue properties of curved-surface AlSi10Mg parts fabricated by powder bed fusion (PBF) additive manufacturing.

Design/methodology/approach

This paper investigated the high-cycle tensile and bending fatigue behaviors of PBF-built AlSi10Mg parts with curved surfaces. Besides, the surface finish, porosity and microstructure around various curvatures were characterized. Meanwhile, the stress distributions of the fatigue specimens with curved surfaces under the dynamic tensile/bending loading were analyzed via theoretical analysis and ANSYS simulation.

Findings

The results showed that the as-built specimens with the smallest curvature exhibited the best surface quality, smallest grain sizes and thinnest grain boundaries. In addition, the tensile fatigue fracture occurred around the largest curvature position of fatigue specimens, which was consistent with the simulated fatigue safety factor results. Moreover, the bending fatigue specimens with the largest curvature presented the shortest fatigue life due to the highest bending and shear stresses along the loading direction.

Originality/value

So far, most studies have focused on the fatigue behavior of as-built AlSi10Mg parts with planar structures only. The investigation on fatigue properties of as-built AlSi10Mg parts with curved surfaces remains unexplored. This study provides new insights into the characterization and quantification of the fatigue performance of PBF-built metal parts with complex geometries, the knowledge of which can promote their adoption in real industries.

Keywords

Acknowledgements

This work has been supported by start-up funds from Thomas J. Watson College of Engineering and Applied Science at the State University of New York at Binghamton, USA. Fuda Ning also would like to acknowledge the support by the ADL small grant from the Small Scale Systems Integration and Packaging (S3IP) Center of Excellence, funded by the New York Empire State Development’s Division of Science, Technology and Innovation. Comments from Dr Scott Schiffres to improve this article are also appreciated.

Citation

Zhou, Y., Abbara, E.M., Jiang, D., Azizi, A., Poliks, M.D. and Ning, F. (2022), "High-cycle fatigue properties of curved-surface AlSi10Mg parts fabricated by powder bed fusion additive manufacturing", Rapid Prototyping Journal, Vol. 28 No. 7, pp. 1346-1360. https://doi.org/10.1108/RPJ-09-2021-0253

Publisher

:

Emerald Publishing Limited

Copyright © 2022, Emerald Publishing Limited

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