Mechanism of microstructure and mechanical properties improvement through ultrasonic rolling pressing layer-by-layer and adaptive ultrasonic rolling method research in AlSi10Mg laser powder bed fused
In the process of laser powder bed fusion (L-PBF), the high-speed movement of the laser heat source causes uneven temperature and stress fields, thus, it results in dendrites, pores, micro cracks and residual stresses. This paper explores a new process of AlSi10Mg alloy grain refinement through ultr...
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Elsevier
2025-07-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425017144 |
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| author | Bo Qian Peng Dai Man Zhao Qiyue Cui Gang Liu Qingsong Wei Ruidi Li Steven Y. Liang |
| author_facet | Bo Qian Peng Dai Man Zhao Qiyue Cui Gang Liu Qingsong Wei Ruidi Li Steven Y. Liang |
| author_sort | Bo Qian |
| collection | DOAJ |
| description | In the process of laser powder bed fusion (L-PBF), the high-speed movement of the laser heat source causes uneven temperature and stress fields, thus, it results in dendrites, pores, micro cracks and residual stresses. This paper explores a new process of AlSi10Mg alloy grain refinement through ultrasonic roller pressing (USRP) mechanical loading in the laser powder bed fusion layer-by-layer manufacturing process, which achieves an increase in density and improves mechanical properties. Experimental results shows that the porosity decreases to 1 %, and it presents nearly equiaxed grains with a grain size of approximately 8 μm. This improves the mechanical properties and plastic strength of the parts in the construction direction, increasing the yield strength to over 405 MPa, tensile strain to over 8 %, maximum compressive strength to over 46 %, and compressive stress to over 600 MPa. With grain refinement, strength and plasticity are both enhanced. Meanwhile, a new adaptive L-PBF-USRP method is proposed. Compared with the fixed mode, the adaptive L-PBF-USRP mode has a more uniform residual stress on the surface and a more significant stress relaxation effect. Using USRP can reduce the deformation and residual stress of the fabricated AlSi10Mg parts. This work provides a new method for designing and manufacturing high-performance alloys, especially for laser powder bed fusion processes of alloy materials. |
| format | Article |
| id | doaj-art-2d8c24000c4f49d7b990e20587b1d9b8 |
| institution | DOAJ |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-2d8c24000c4f49d7b990e20587b1d9b82025-08-20T03:13:11ZengElsevierJournal of Materials Research and Technology2238-78542025-07-01374120413510.1016/j.jmrt.2025.07.056Mechanism of microstructure and mechanical properties improvement through ultrasonic rolling pressing layer-by-layer and adaptive ultrasonic rolling method research in AlSi10Mg laser powder bed fusedBo Qian0Peng Dai1Man Zhao2Qiyue Cui3Gang Liu4Qingsong Wei5Ruidi Li6Steven Y. Liang7School of Mechanical and Automotive Engineering, Shanghai University of Engineering Science, Shanghai, 201620, China; Corresponding author.School of Mechanical and Automotive Engineering, Shanghai University of Engineering Science, Shanghai, 201620, ChinaSchool of Mechanical and Automotive Engineering, Shanghai University of Engineering Science, Shanghai, 201620, China; Corresponding author.School of Mechanical and Automotive Engineering, Shanghai University of Engineering Science, Shanghai, 201620, ChinaSchool of Mechanical and Automotive Engineering, Shanghai University of Engineering Science, Shanghai, 201620, ChinaSchool of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, ChinaState Key Laboratory of Powder Metallurgy, Central South University, Changsha, 410083, ChinaWoodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, USAIn the process of laser powder bed fusion (L-PBF), the high-speed movement of the laser heat source causes uneven temperature and stress fields, thus, it results in dendrites, pores, micro cracks and residual stresses. This paper explores a new process of AlSi10Mg alloy grain refinement through ultrasonic roller pressing (USRP) mechanical loading in the laser powder bed fusion layer-by-layer manufacturing process, which achieves an increase in density and improves mechanical properties. Experimental results shows that the porosity decreases to 1 %, and it presents nearly equiaxed grains with a grain size of approximately 8 μm. This improves the mechanical properties and plastic strength of the parts in the construction direction, increasing the yield strength to over 405 MPa, tensile strain to over 8 %, maximum compressive strength to over 46 %, and compressive stress to over 600 MPa. With grain refinement, strength and plasticity are both enhanced. Meanwhile, a new adaptive L-PBF-USRP method is proposed. Compared with the fixed mode, the adaptive L-PBF-USRP mode has a more uniform residual stress on the surface and a more significant stress relaxation effect. Using USRP can reduce the deformation and residual stress of the fabricated AlSi10Mg parts. This work provides a new method for designing and manufacturing high-performance alloys, especially for laser powder bed fusion processes of alloy materials.http://www.sciencedirect.com/science/article/pii/S2238785425017144Ultrasonic roll pressingLaser powder bed fusionGrain refinementResidual stressAdaptive control |
| spellingShingle | Bo Qian Peng Dai Man Zhao Qiyue Cui Gang Liu Qingsong Wei Ruidi Li Steven Y. Liang Mechanism of microstructure and mechanical properties improvement through ultrasonic rolling pressing layer-by-layer and adaptive ultrasonic rolling method research in AlSi10Mg laser powder bed fused Journal of Materials Research and Technology Ultrasonic roll pressing Laser powder bed fusion Grain refinement Residual stress Adaptive control |
| title | Mechanism of microstructure and mechanical properties improvement through ultrasonic rolling pressing layer-by-layer and adaptive ultrasonic rolling method research in AlSi10Mg laser powder bed fused |
| title_full | Mechanism of microstructure and mechanical properties improvement through ultrasonic rolling pressing layer-by-layer and adaptive ultrasonic rolling method research in AlSi10Mg laser powder bed fused |
| title_fullStr | Mechanism of microstructure and mechanical properties improvement through ultrasonic rolling pressing layer-by-layer and adaptive ultrasonic rolling method research in AlSi10Mg laser powder bed fused |
| title_full_unstemmed | Mechanism of microstructure and mechanical properties improvement through ultrasonic rolling pressing layer-by-layer and adaptive ultrasonic rolling method research in AlSi10Mg laser powder bed fused |
| title_short | Mechanism of microstructure and mechanical properties improvement through ultrasonic rolling pressing layer-by-layer and adaptive ultrasonic rolling method research in AlSi10Mg laser powder bed fused |
| title_sort | mechanism of microstructure and mechanical properties improvement through ultrasonic rolling pressing layer by layer and adaptive ultrasonic rolling method research in alsi10mg laser powder bed fused |
| topic | Ultrasonic roll pressing Laser powder bed fusion Grain refinement Residual stress Adaptive control |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425017144 |
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