Mapping residual stresses in AlSi10Mg alloy fabricated by powder bed fusion-laser beam method
Abstract Residual stresses in metal alloys fabricated by the powder bed fusion-laser beam (PBF-LB) method exhibit anisotropy influenced by laser scanning and building orientations. This study maps nanoscale residual stresses within a single grain of PBF-LB AlSi10Mg alloy using various transmission e...
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Nature Portfolio
2025-07-01
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| Series: | Scientific Reports |
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| Online Access: | https://doi.org/10.1038/s41598-025-09316-0 |
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| author | Mohamed E. Daoud Inas Taha Ahmed Abdelgawad Imad Barsoum Kamran A. Khan Dalaver H. Anjum |
| author_facet | Mohamed E. Daoud Inas Taha Ahmed Abdelgawad Imad Barsoum Kamran A. Khan Dalaver H. Anjum |
| author_sort | Mohamed E. Daoud |
| collection | DOAJ |
| description | Abstract Residual stresses in metal alloys fabricated by the powder bed fusion-laser beam (PBF-LB) method exhibit anisotropy influenced by laser scanning and building orientations. This study maps nanoscale residual stresses within a single grain of PBF-LB AlSi10Mg alloy using various transmission electron microscopy (TEM) modalities. Residual stress maps were obtained for both as-built and T6 heat-treated samples along scanning and building orientations. Post-analysis revealed that T6 heat treatment reduced tensile stress compared to as-built samples. For example, in the [1̅00] crystallographic direction, average tensile and compressive residual stresses in the building direction decreased by ~ 70% after T6 treatment. Anisotropy in residual stresses was also observed; in the [1̅00] direction, average residual stresses in scanning orientation were ~ 13% and ~ 23% higher than the building direction in as-built and T6-treated samples, respectively. Heat treatment effects were further examined using image-based finite element method (FEM) simulations to understand the stress-driven mechanisms behind Si eutectic break-up and Si precipitate diffusion into the Al matrix. The results revealed regions of tensile and compressive stress within Si eutectic zones, identifying them as sources for Si diffusion and nucleation of Si-based precipitates within the matrix. |
| format | Article |
| id | doaj-art-61fcad48268341da8474f28dbf258946 |
| institution | DOAJ |
| issn | 2045-2322 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Nature Portfolio |
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| spelling | doaj-art-61fcad48268341da8474f28dbf2589462025-08-20T03:04:25ZengNature PortfolioScientific Reports2045-23222025-07-0115111810.1038/s41598-025-09316-0Mapping residual stresses in AlSi10Mg alloy fabricated by powder bed fusion-laser beam methodMohamed E. Daoud0Inas Taha1Ahmed Abdelgawad2Imad Barsoum3Kamran A. Khan4Dalaver H. Anjum5Department of Physics, Khalifa UniversityDepartment of Physics, Khalifa UniversityDepartment of Mechanical Engineering, Khalifa UniversityDepartment of Mechanical Engineering, Khalifa UniversityAerospace Engineering Department, Khalifa UniversityDepartment of Physics, Khalifa UniversityAbstract Residual stresses in metal alloys fabricated by the powder bed fusion-laser beam (PBF-LB) method exhibit anisotropy influenced by laser scanning and building orientations. This study maps nanoscale residual stresses within a single grain of PBF-LB AlSi10Mg alloy using various transmission electron microscopy (TEM) modalities. Residual stress maps were obtained for both as-built and T6 heat-treated samples along scanning and building orientations. Post-analysis revealed that T6 heat treatment reduced tensile stress compared to as-built samples. For example, in the [1̅00] crystallographic direction, average tensile and compressive residual stresses in the building direction decreased by ~ 70% after T6 treatment. Anisotropy in residual stresses was also observed; in the [1̅00] direction, average residual stresses in scanning orientation were ~ 13% and ~ 23% higher than the building direction in as-built and T6-treated samples, respectively. Heat treatment effects were further examined using image-based finite element method (FEM) simulations to understand the stress-driven mechanisms behind Si eutectic break-up and Si precipitate diffusion into the Al matrix. The results revealed regions of tensile and compressive stress within Si eutectic zones, identifying them as sources for Si diffusion and nucleation of Si-based precipitates within the matrix.https://doi.org/10.1038/s41598-025-09316-0Residual stressesPowder bed fusion-laser beamAlSi10Mg alloyAnisotropyTransmission Electron microscopyFinite element method |
| spellingShingle | Mohamed E. Daoud Inas Taha Ahmed Abdelgawad Imad Barsoum Kamran A. Khan Dalaver H. Anjum Mapping residual stresses in AlSi10Mg alloy fabricated by powder bed fusion-laser beam method Scientific Reports Residual stresses Powder bed fusion-laser beam AlSi10Mg alloy Anisotropy Transmission Electron microscopy Finite element method |
| title | Mapping residual stresses in AlSi10Mg alloy fabricated by powder bed fusion-laser beam method |
| title_full | Mapping residual stresses in AlSi10Mg alloy fabricated by powder bed fusion-laser beam method |
| title_fullStr | Mapping residual stresses in AlSi10Mg alloy fabricated by powder bed fusion-laser beam method |
| title_full_unstemmed | Mapping residual stresses in AlSi10Mg alloy fabricated by powder bed fusion-laser beam method |
| title_short | Mapping residual stresses in AlSi10Mg alloy fabricated by powder bed fusion-laser beam method |
| title_sort | mapping residual stresses in alsi10mg alloy fabricated by powder bed fusion laser beam method |
| topic | Residual stresses Powder bed fusion-laser beam AlSi10Mg alloy Anisotropy Transmission Electron microscopy Finite element method |
| url | https://doi.org/10.1038/s41598-025-09316-0 |
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