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Enhancing the properties of friction stir welded joints of L-PBF printed AlSi10Mg alloy via multi-variable optimization

Minhas Navdeep, Sharma Varun, Bhadauria Shailendra Singh

Archives of Civil and Mechanical Engineering

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2023

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Vol. 23, no. 1

art. no. e60, 2023

EN

The feasibility study to join the laser powder bed fused AlSi10Mg alloy sheets using different friction stir welding parameters was investigated in the present work. Fifteen butt-welded joints using varied parametric combinations were developed based on the design of the experiment's approach. An empirical model between the process parameters and tensile strength was developed and used to understand the mechanical behavior of the welded joints w.r.t. the FSW parameters, followed by the attainment of optimized welding conditions using response surface methodology. The results inferred that the weldability was most significantly influenced by the tool rotational speed, followed by the tool tilt angle and tool traverse speed. The microstructure and mechanical properties of the optimized welded joint were compared with the as-built alloy and the welded joint yielding minimum tensile strength. The electron back scattered diffraction analysis revealed the reduction of average grain size of the stir zone of the joints by 21% for the optimized weld, as compared to the as-built alloy. The welded zones of the joints showed a reduction in hardness by 40-50% and formed the stir zone as the weakest link. The parametric combinations of the optimized weld improved the joint efficiency by ≈ 20% compared to the other weld, followed by an improvement in ductility, which was further characterized using scanning electron microscopy.

2

The influence of AlSi10Mg recycled powder on corrosion-resistance behaviour of additively manufactured components: mechanical aspects and acoustic emission investigation

Barile Claudia, Casavola Caterina, Kannan Vimalathithan Paramsamy, Renna Gilda

Archives of Civil and Mechanical Engineering

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2022

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Vol. 22, no. 1

art. no. e52, 2022

EN

The effects of using recycled AlSi10Mg aluminium alloy powders on the mechanical properties and the corrosion-resistance behaviour of the components manufactured via selective laser melting (SLM) were analysed. The microstructural results show that the utilisation of recycled powder causes coarsening of interdendritic Si-network, especially along the melt pool boundaries of the SLM specimens. The corrosion resistance of the samples was evaluated by means of neutral salt spray (NSS) tests for 1000 h and mass loss measurements. The corrosion behaviour, in terms of surface roughness, density and porosity, however, remains almost the same between the samples produced by virgin and recycled powder. In addition to this, a passive NDE tool has been used to investigate and study the impact of powders on the corrosion performance of the alloy: Acoustic Emission (AE) technique. SEM observations allowed to highlight the morphological differences in the surface of the test specimens induced by the exposure condition. Thus, it was possible to correlate the AE results to corrosion mechanisms activated on the surfaces of the test specimen. A good correlation between the corrosion-resistance behaviour and the AE test results were obtained. Finally, the mechanical properties before and at the end of the accelerated corrosion were evaluated according to the yield strength, tensile strength, and elongation at breakage. The results showed comparable mechanical properties for the samples produced using both virgin and recycled powders. Besides, no notable influence of the exposure to corrosive environment on the mechanical performance was observed.

3

Residual Stresses of AlSi10Mg Fabricated by Selective Laser Melting (SLM)

Karolus M., Maszybrocka J., Stwora A., Skrabalak G.

Archives of Metallurgy and Materials

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2019

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Vol. 64, iss. 3

1011--1016

EN

The aim of the paper is the residual stress analysis of AlSi10Mg material fabricated by selective laser melting (SLM). The SLM technique allows to product of complex geometries based on three-dimensional model, in which stiffness and porosity can be precisely designed for specific uses. As the studied material, there were chosen solid samples built in two different directions: parallel (P-L) and perpendicular (P-R) to the tested surface and cellular lattice built in perpendicular direction, as well. In the paper, for the complex characterization of obtained materials, the phase analysis, residual stress and texture studies were performed. The classical non-destructive sin2ψ method was used to measure the residual stress measurements. The final products, both solid sample and cellular lattice, have a homogeneous phase composition and consist of solid solution Al(Si) (Fm-3m) type, Si (Fd-3m) and Mg2 Si (Pnma). The obtained values of the crystallite size are in a range of 1000 Å for Al(Si), 130-180 Å for Si phase. For Mg2 Si phase, the crystallite sizes depend on sintering process, they are 800 Å for solid samples and 107 Å for cellular lattice. The residual stress results have the compressive character and they are in a range from –5 to –15 MPa.

4

Powstawanie zadziorów przy frezowaniu współbieżnym i przeciwbieżnym stopu AlSi10Mg

Falkowicz K., Kuczmaszewski J.

Przegląd Mechaniczny

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2012

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nr 9

23-27

PL

Operacje usuwania zadziorów są dość kosztowne, dlatego też znajomość tworzenia się zadziorów pozwala na uwypuklenie istotności tego zagadnienia w świetle ogólnie rozumianej obróbki skrawaniem. W artykule przedstawiony został? mechanizm formowania si´ zadziorów w procesie frezowania czołowego stopu AlSi10Mg. Zbadano również wpływ poszczególnych parametrów obróbki na wielkość powstających zadziorów.

EN

Since deburring is a costly and non-value-adding operation, the understanding and control of burr formation is a research topic with high relevance to industrial applications. The purpose of this paper was to study the burr formation mechanisms in face milling process of aluminum alloy AlSi10Mg, and to investigate the influence of machining parameters on burr formation in face milling.