An improved process scan strategy to obtain high-performance fatigue properties for Scalmalloy®
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In: Materials and Design, Vol. 224.2022, No. December, 111410, 22.11.2022.
Research output: Contribution to journal › Article › Research › peer-review
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TY - JOUR
T1 - An improved process scan strategy to obtain high-performance fatigue properties for Scalmalloy®
AU - Schimbäck, David
AU - Mair, P.
AU - Kaserer, L.
AU - Perfler, L.
AU - Palm, F.
AU - Leichtfried, G.
AU - Pogatscher, Stefan
N1 - Publisher Copyright: © 2022 The Author(s)
PY - 2022/11/22
Y1 - 2022/11/22
N2 - The choice of appropriate processing parameters in laser powder bed fusion is firmly established in the state-of-the-art additive manufacturing community. However, optimisation of scanning strategy would result in improved material properties. Here, the optimal scanning strategy for fatigue-loaded high-performance aluminium alloys, such as Scalmalloy®, was investigated. This study demonstrates how to reduce uncontrolled interactions of the laser with the distinct weld plume, created by highly volatile alloying elements such as Mg. Tensile and fatigue testing were used to assess the structural integrity of specimens, in which different welding modes had been used. It is shown that a combination of: scan vector angle restriction; reduction of the scan vector length; and laser spot adjustments reduce the overall defect size and improves the build quality in Scalmalloy®. A bimodal microstructure with outstanding mechanical properties was observed: an ultimate tensile strength of 524 MPa was achieved with 17 % elongation at fracture. In order to evaluate the influence of the defect size, fatigue tests were performed at a stress ratio of . Under optimal processing conditions, fatigue strengths of up to at cycles were obtained, significantly outperforming both conventionally and additively produced aluminium alloys.
AB - The choice of appropriate processing parameters in laser powder bed fusion is firmly established in the state-of-the-art additive manufacturing community. However, optimisation of scanning strategy would result in improved material properties. Here, the optimal scanning strategy for fatigue-loaded high-performance aluminium alloys, such as Scalmalloy®, was investigated. This study demonstrates how to reduce uncontrolled interactions of the laser with the distinct weld plume, created by highly volatile alloying elements such as Mg. Tensile and fatigue testing were used to assess the structural integrity of specimens, in which different welding modes had been used. It is shown that a combination of: scan vector angle restriction; reduction of the scan vector length; and laser spot adjustments reduce the overall defect size and improves the build quality in Scalmalloy®. A bimodal microstructure with outstanding mechanical properties was observed: an ultimate tensile strength of 524 MPa was achieved with 17 % elongation at fracture. In order to evaluate the influence of the defect size, fatigue tests were performed at a stress ratio of . Under optimal processing conditions, fatigue strengths of up to at cycles were obtained, significantly outperforming both conventionally and additively produced aluminium alloys.
KW - Fatigue
KW - Laser Powder Bed Fusion
KW - Parameter Study
KW - Scalmalloy
KW - Welding Mode
UR - http://www.scopus.com/inward/record.url?scp=85142473833&partnerID=8YFLogxK
U2 - 10.1016/j.matdes.2022.111410
DO - 10.1016/j.matdes.2022.111410
M3 - Article
AN - SCOPUS:85142473833
VL - 224.2022
JO - Materials and Design
JF - Materials and Design
SN - 0264-1275
IS - December
M1 - 111410
ER -