L-DED and L-PBF Additive Manufactured AlSi10Mg Alloy: Mechanical Characterization and Very-High Cycle Fatigue Performance
Aluminum (Al) parts for the electrical industry are subjected to cyclic loads, making their fatigue life critical. Owing to its properties, AlSi10Mg alloy is largely employed in this field. Additive manufacturing (AM) is rising as a new technology to fulfill the demand for spare parts. Laser Directe...
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Associação Brasileira de Metalurgia e Materiais (ABM); Associação Brasileira de Cerâmica (ABC); Associação Brasileira de Polímeros (ABPol)
2025-08-01
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| author | Alexandre Pinhel Soares Anselmo Thiesen Junior Marcos Vinicius Bento Henrique Santos Ferreira Carlos Eduardo Bibow Correa Emili Bettinelli Jurandir Marcos Sá de Sousa |
| author_facet | Alexandre Pinhel Soares Anselmo Thiesen Junior Marcos Vinicius Bento Henrique Santos Ferreira Carlos Eduardo Bibow Correa Emili Bettinelli Jurandir Marcos Sá de Sousa |
| author_sort | Alexandre Pinhel Soares |
| collection | DOAJ |
| description | Aluminum (Al) parts for the electrical industry are subjected to cyclic loads, making their fatigue life critical. Owing to its properties, AlSi10Mg alloy is largely employed in this field. Additive manufacturing (AM) is rising as a new technology to fulfill the demand for spare parts. Laser Directed Energy Deposition (L-DED) and Laser Powder Bed Fusion (L-PBF) can manufacture customized components with larger dimensions and greater geometric resolution, respectively. However, there are challenges in processing AlSi10Mg by AM, like controlling oxygen and moisture atmosphere contents, which negatively affect the processability and component properties. To ensure multilayer parts with appropriate microstructure and mechanical properties, L-DED and L-PBF processing parameters must be properly investigated. In this context, processing parameters and build strategies for an AlSi10Mg alloy were developed for L-DED and L-PBF. The performance of AM-manufactured AlSi10Mg was benchmarked to reference casting. Archimedes’ density, optical microscopy porosity, computed tomography, optical and scanning electron microscopy, hardness, tensile, Charpy impact, and VHCF tests were performed. The results suggest comparable VHCF performance, despite the slight differences observed in mechanical properties, porosity, and microstructure characteristics between L-PBF and L-DED specimens. |
| format | Article |
| id | doaj-art-dd2ccfc003cd4ed6bef70cc5f9f0fb5f |
| institution | Kabale University |
| issn | 1516-1439 |
| language | English |
| publishDate | 2025-08-01 |
| publisher | Associação Brasileira de Metalurgia e Materiais (ABM); Associação Brasileira de Cerâmica (ABC); Associação Brasileira de Polímeros (ABPol) |
| record_format | Article |
| series | Materials Research |
| spelling | doaj-art-dd2ccfc003cd4ed6bef70cc5f9f0fb5f2025-08-20T03:45:07ZengAssociação Brasileira de Metalurgia e Materiais (ABM); Associação Brasileira de Cerâmica (ABC); Associação Brasileira de Polímeros (ABPol)Materials Research1516-14392025-08-0128suppl 110.1590/1980-5373-mr-2025-0242L-DED and L-PBF Additive Manufactured AlSi10Mg Alloy: Mechanical Characterization and Very-High Cycle Fatigue PerformanceAlexandre Pinhel Soareshttps://orcid.org/0000-0001-8644-5235Anselmo Thiesen Juniorhttps://orcid.org/0000-0002-1466-5439Marcos Vinicius BentoHenrique Santos Ferreirahttps://orcid.org/0000-0002-7602-1022Carlos Eduardo Bibow CorreaEmili BettinelliJurandir Marcos Sá de Sousahttps://orcid.org/0000-0002-2132-5766Aluminum (Al) parts for the electrical industry are subjected to cyclic loads, making their fatigue life critical. Owing to its properties, AlSi10Mg alloy is largely employed in this field. Additive manufacturing (AM) is rising as a new technology to fulfill the demand for spare parts. Laser Directed Energy Deposition (L-DED) and Laser Powder Bed Fusion (L-PBF) can manufacture customized components with larger dimensions and greater geometric resolution, respectively. However, there are challenges in processing AlSi10Mg by AM, like controlling oxygen and moisture atmosphere contents, which negatively affect the processability and component properties. To ensure multilayer parts with appropriate microstructure and mechanical properties, L-DED and L-PBF processing parameters must be properly investigated. In this context, processing parameters and build strategies for an AlSi10Mg alloy were developed for L-DED and L-PBF. The performance of AM-manufactured AlSi10Mg was benchmarked to reference casting. Archimedes’ density, optical microscopy porosity, computed tomography, optical and scanning electron microscopy, hardness, tensile, Charpy impact, and VHCF tests were performed. The results suggest comparable VHCF performance, despite the slight differences observed in mechanical properties, porosity, and microstructure characteristics between L-PBF and L-DED specimens.http://www.scielo.br/scielo.php?script=sci_arttext&pid=S1516-14392025000200281&lng=en&tlng=enElectrical IndustryAlSi10MgAdditive ManufacturingL-DEDL-PBFMechanical PerformanceVHCFFatigue |
| spellingShingle | Alexandre Pinhel Soares Anselmo Thiesen Junior Marcos Vinicius Bento Henrique Santos Ferreira Carlos Eduardo Bibow Correa Emili Bettinelli Jurandir Marcos Sá de Sousa L-DED and L-PBF Additive Manufactured AlSi10Mg Alloy: Mechanical Characterization and Very-High Cycle Fatigue Performance Materials Research Electrical Industry AlSi10Mg Additive Manufacturing L-DED L-PBF Mechanical Performance VHCF Fatigue |
| title | L-DED and L-PBF Additive Manufactured AlSi10Mg Alloy: Mechanical Characterization and Very-High Cycle Fatigue Performance |
| title_full | L-DED and L-PBF Additive Manufactured AlSi10Mg Alloy: Mechanical Characterization and Very-High Cycle Fatigue Performance |
| title_fullStr | L-DED and L-PBF Additive Manufactured AlSi10Mg Alloy: Mechanical Characterization and Very-High Cycle Fatigue Performance |
| title_full_unstemmed | L-DED and L-PBF Additive Manufactured AlSi10Mg Alloy: Mechanical Characterization and Very-High Cycle Fatigue Performance |
| title_short | L-DED and L-PBF Additive Manufactured AlSi10Mg Alloy: Mechanical Characterization and Very-High Cycle Fatigue Performance |
| title_sort | l ded and l pbf additive manufactured alsi10mg alloy mechanical characterization and very high cycle fatigue performance |
| topic | Electrical Industry AlSi10Mg Additive Manufacturing L-DED L-PBF Mechanical Performance VHCF Fatigue |
| url | http://www.scielo.br/scielo.php?script=sci_arttext&pid=S1516-14392025000200281&lng=en&tlng=en |
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