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Influence of LPBF-Surface Characteristics on Fatigue Properties of Scalmalloy®

Musekamp, Jens ; Reiber, Thorsten ; Hoche, Holger Claus ; Oechsner, Matthias ; Weigold, Matthias ; Abele, Eberhard (2021)
Influence of LPBF-Surface Characteristics on Fatigue Properties of Scalmalloy®.
In: Metals, 11 (12)
doi: 10.3390/met11121961
Article, Bibliographie

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Abstract

Laser powder bed fusion (LPBF) has indisputable advantages when designing new components with complex geometries due to toolless manufacturing and the ability to manufacture components with undercuts. However, fatigue properties rely heavily on the surface condition. In this work, in-process surface parameters (three differing contour parameter sets) and post-process surface treatments, namely turning and shot peening, are varied to investigate the influence of each treatment on the resulting fatigue properties of LPBF-manufactured specimens of the aluminium--magnesium--scandium alloy Scalmalloy\circledR. Therefore, metallographic analysis and surface roughness measurements, as well as residual stress measurements, computer tomography measurements, SEM-analyses, tensile and fatigue tests, along with fracture surface analysis, were performed. Despite the fact that newly developed in-process contour parameters are able to reduce the surface roughness significantly, only a minor improvement in fatigue properties could be observed: Crack initiation is caused by sharp, microscopic notches at the surface in combination with high tensile residual stresses at the surface, which are present on all in-process contour parameter specimens. Specimens using contour parameters with high line energy show keyhole pores localized in the subsurface area, which have no effect on crack initiation. Contours with low line energy have a slightly positive effect on fatigue strength because less pores can be found at the surface and subsurface area, which even more greatly promotes an early crack initiation. The post-process parameter sets, turning and shot peening, both improve fatigue behaviour significantly: Turned specimens show lowest surface roughness, while, for shot peened specimens, the tensile residual stresses of the surface radially shifted from the surface towards the centre of the specimens, which counteracts the crack initiation at the surface.

Item Type: Article
Erschienen: 2021
Creators: Musekamp, Jens ; Reiber, Thorsten ; Hoche, Holger Claus ; Oechsner, Matthias ; Weigold, Matthias ; Abele, Eberhard
Type of entry: Bibliographie
Title: Influence of LPBF-Surface Characteristics on Fatigue Properties of Scalmalloy®
Language: English
Date: 2021
Publisher: MDPI
Journal or Publication Title: Metals
Volume of the journal: 11
Issue Number: 12
DOI: 10.3390/met11121961
URL / URN: https://www.mdpi.com/2075-4701/11/12/1961
Corresponding Links:
Abstract:

Laser powder bed fusion (LPBF) has indisputable advantages when designing new components with complex geometries due to toolless manufacturing and the ability to manufacture components with undercuts. However, fatigue properties rely heavily on the surface condition. In this work, in-process surface parameters (three differing contour parameter sets) and post-process surface treatments, namely turning and shot peening, are varied to investigate the influence of each treatment on the resulting fatigue properties of LPBF-manufactured specimens of the aluminium--magnesium--scandium alloy Scalmalloy\circledR. Therefore, metallographic analysis and surface roughness measurements, as well as residual stress measurements, computer tomography measurements, SEM-analyses, tensile and fatigue tests, along with fracture surface analysis, were performed. Despite the fact that newly developed in-process contour parameters are able to reduce the surface roughness significantly, only a minor improvement in fatigue properties could be observed: Crack initiation is caused by sharp, microscopic notches at the surface in combination with high tensile residual stresses at the surface, which are present on all in-process contour parameter specimens. Specimens using contour parameters with high line energy show keyhole pores localized in the subsurface area, which have no effect on crack initiation. Contours with low line energy have a slightly positive effect on fatigue strength because less pores can be found at the surface and subsurface area, which even more greatly promotes an early crack initiation. The post-process parameter sets, turning and shot peening, both improve fatigue behaviour significantly: Turned specimens show lowest surface roughness, while, for shot peened specimens, the tensile residual stresses of the surface radially shifted from the surface towards the centre of the specimens, which counteracts the crack initiation at the surface.

Uncontrolled Keywords: Aluminium alloys, fatigue, Laser powder bed fusion, post processing, stress measurements
Divisions: 16 Department of Mechanical Engineering
16 Department of Mechanical Engineering > Center for Engineering Materials, State Materials Testing Institute Darmstadt (MPA) Chair and Institute for Materials Technology (IfW)
16 Department of Mechanical Engineering > Institute of Production Technology and Machine Tools (PTW)
16 Department of Mechanical Engineering > Institute of Production Technology and Machine Tools (PTW) > TEC Manufacturing Technology
Date Deposited: 08 Dec 2021 07:08
Last Modified: 12 Dec 2023 12:54
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