A review of selective laser melting of aluminum alloys: Processing, microstructure, property and developing trends

https://research.birmingham.ac.uk/portal/files/29849905/A_16_1391R1_2_.pdf

Microstructure and strength of selectively laser melted AlSi10Mg

Mechanical response of Ti–6Al–4V octet-truss lattice structures

Excellent thermal conductivity and lower density make Al–Si alloys a suitable alternative for cast iron in the fabrication of engine components. The increase in the maximum operation temperature and pressure of engines necessitates improving the thermomechanical fatigue performance of Al–Si alloys. This paper has two major parts focussing on the use of Al–Si based alloys in cylinder heads and engine blocks.In the first part, the structural stress–strain and material property requirements of cylinder heads are discussed. In addition, the physical and mechanical properties of different competing materials used in the manufacture of engine components are reviewed. The physical metallurgy, solidification sequence and thermal conductivity of Al–Si based alloys are reviewed. Also discussed is the effect of microstructural features on thermomechanical fatigue lifetime. This part also includes an overview of the strengthening mechanisms of cast Al–Si alloys, by dispersed phases and heat treatment.Demands ...

Application of cast Al–Si alloys in internal combustion engine components

We describe here a comprehensive study on the effect of cellular structure and melt pool boundary (MPB) condition on the mechanical properties, deformation and failure behavior of AlSi10Mg alloy processed by selective laser melting (SLM). The morphology of melt pool (MP) on the load bearing face of tensile samples was significantly different with build directions. It resulted in different mechanical properties of the samples with different build directions. Furthermore, the microstructure analysis revealed that the MP in the SLM AlSi10Mg alloy mainly consisted of columnar α-Al grains which were made of ultra-fine elongated cellular structure. Electron back-scatter diffraction (EBSD) analysis revealed that the long axis of cellular structure and columnar grains were parallel to , which resulted in  fiber texture in SLM AlSi10Mg alloy. However, Schmid factor calculation demonstrated that the anisotropy of mechanical properties of the SLM AlSi10Mg alloy built with different direction was mainly dependent on the distribution of MPB on the load bearing face, and not texture. The defects including pores, residual stress and heat affected zone (HAZ) located at MPB made it the weakest part in the SLM AlSi10Mg. The sample built along horizontal direction exhibited good combination of strength and plasticity and is attributed to the lowest fraction of MPBs that withstand load during tensile. MPB had strong influence on the mechanical properties and failure behavior of SLM AlSi10Mg built with different directions.

Role of melt pool boundary condition in determining the mechanical properties of selective laser melting AlSi10Mg alloy

The development of Al-Si alloy and its based material for engine application is reported in this paper, focusing on improving the material’s fatigue limit and wear resistance, which are two important properties for engine block materials. The paper begins with a description of the microstructure (primary and eutectic phases, intermetallics, and casting defects) of Al-Si alloy and its effects on this material’s fatigue and wear behaviors. Then, some recent techniques to enhance these two properties are discussed such as alloying, composite production, and casting.

Haizhi Ye

Papers

An overview of the development of Al-Si-Alloy based material for engine applications