Eklemeli Üretim Yöntemiyle Üretilen AlSi10Mg Alaşımlarının Üretim Süreçleri, Mikroyapısal Özellikleri, Isıl İşlem Stratejileri, Mekanik ve Yorulma Davranışları

Öz

AlSi10Mg alüminyum alaşımları, düşük yoğunlukları, yüksek özgül ağırlıkları/mukavemetleri, iyi dökülebilirlikleri ve elverişli ısı özellikleri nedeniyle eklemeli imalatta (AM) yaygın olarak kullanılmaktadır. Lazer tabanlı toz yataklı füzyon (LPBF) ve yönlendirilmiş enerji biriktirme (DED) teknikleri, karmaşık geometrilere, neredeyse nihai şekle sahip ve ayarlanabilir mikroyapı özelliklerine ihtiyaç duyan parçaların üretimi için en uygun yöntemler arasında kabul edilmektedir. Bu çalışma, eklemeli imalat yöntemleriyle üretilen yüksek performanslı AlSi10Mg alaşımlarının kapsamlı bir incelemesini sunmaktadır. Bölüm, üretim süreçlerini, mikroyapı özelliklerini, ısıl işlem stratejilerini, mekanik ve yorulma davranışını, mevcut zorlukları ve gelecekteki araştırma eğilimlerini kapsamaktadır.

Anahtar Kelimeler

• AlSi10Mg
• Lazer toz yataklı eritme (LPBM)
• Katmanlı imalat (AM)
• Isıl işlem
• Mikro yapı ve Mekanik özellikler

Production Processes, Microstructural Properties, Heat Treatment Strategies, Mechanical and Fatigue Behavior of AlSi10Mg Alloys Produced by Additive Manufacturing Method

Öz

AlSi10Mg aluminum alloys are widely used in additive manufacturing (AM) due to their low density, high specific gravity/strength, good castability, and favorable heat properties. Laser-based powder bed fusion (LPBF) and directed energy deposition (DED) techniques are considered among the most suitable methods for producing parts with complex geometries, near-net shape, and requiring adjustable microstructure properties. This study presents a comprehensive review of high-performance AlSi10Mg alloys produced by additive manufacturing methods. The chapter covers production processes, microstructural properties, heat treatment strategies, mechanical and fatigue behavior, current challenges, and future research trends.

Anahtar Kelimeler

• AlSi10Mg
• Laser powder bed melting (LPBM)
• Additive manufacturing (AM)
• Heat treatment
• Microstructure and Mechanical properties

Kaynakça

1. Anil KR, R DT, K KR, Joshi C, Chouhan RN, Agnihotri A. A review on the correlation between microstructure, heat treatment and mechanical properties of additively manufactured AlSi10Mg by LPBF. Crit Rev Solid State Mater Sci 2024: 1–36. https://doi.org/10.1080/10408436.2024.2414012. 0.
2. Hernandez, F. C. R.; Ramırez, J. M. H.; Mackay, R. Al-Si Alloys: Automotive. Aeronautical, and Aerospace Applications; Springer: Cham, 2017. doi:10.1007/978- 3-319-58380-8.
3. Hasanov, S.; Alkunte, S.; Rajeshirke, M.; Gupta, A.; Huseynov, O.; Fidan, I.; Alifui-Segbaya, F.; Rennie, A. Review on Additive Manufacturing of Multi-Material Parts: Progress and Challenges. JMMP. 2021, 6, 4. doi:10.3390/jmmp6010004
4. Raja A, Cheethirala SR, Gupta P, Vasa NJ, Jayaganthan R. A review on the fatigue behaviour of AlSi10Mg alloy fabricated using laser powder bed fusion technique. J Mater Res Technol 2022;17:1013–29. https://doi.org/10.1016/j. jmrt.2022.01.028.
5. ASTM52900-21 Additive Manufacturing—General Principles—Fundamentals and Vocabulary. ASTM International. 2021.
6. Johnson QC, Laursen CM, Spear AD, Carroll JD, Noell PJ. Analysis of the interdependent relationship between porosity, deformation, and crack growth during compression loading of LPBF AlSi10Mg. Mater Sci Eng, A 2022;852:143640. https://doi.org/10.1016/j.msea.2022.143640.
7. Linkan B.; Nima S.; John U. Laser-Based Additive Manufacturing of Metal Parts; CRC Press, 2018.
8. Kimura, T.; Nakamoto, T.; Mizuno, M.; Araki, H. Effect of Silicon Content on Densification, Mechanical and Thermal Properties of Al-XSi Binary Alloys Fabricated Using Selective Laser Melting. Mater. Sci. Eng, A. 2017, 682, 593–602. doi:10.1016/j. msea.2016.11.0

9. Li P, Kim Y, Bobel AC, Hector LG, Sachdev AK, Kumar S, et al. Microstructural origin of the anisotropic flow stress of laser powder bed fused AlSi10Mg. Acta Mater 2021;220. https://doi.org/10.1016/j.actamat.2021.117346.
10. Zhang X, Chen S, Wang Z, Li D, Cui X, Xu J. Effect of cooling rates and heat treatment time on Si phase of AlSi10Mg alloy manufactured by selective laser melting: microstructure evolution and strengthening mechanism. J Alloys Compd 2024;1007:176494. https://doi.org/10.1016/j.jallcom.2024.176494.
11. Liu, P.; Wu, M.; Wu, G. Effect of Laser Power on Microstructure and Mechanical Properties of Selective Laser Melted AlSi10Mg Alloy. J. Phys: Conf. Ser. 2023, 2587, 012008. doi:10.1088/1742-6596/2587/ 1/012008.
12. Santos Macías JG, Douillard T, Zhao L, Maire E, Pyka G, Simar A. Influence on microstructure, strength and ductility of build platform temperature during laser powder bed fusion of AlSi10Mg. Acta Mater 2020;201:231–43. https://doi.org/10.1016/j.actamat.2020.10.001.
13. Aboulkhair, N. T., Simonelli, M., Parry, L., Ashcroft, I., Tuck, C., & Hague, R. 3D printing of aluminium alloys: Additive manufacturing of aluminium alloys using selective laser melting. Progress in Materials Science, 2019. 106, 100578.
14. Frazier, W. E. Metal additive manufacturing: A review. Journal of Materials Engineering and Performance, 2014. 23(6), 1917–1928.
15. Buchbinder, D., Meiners, W., Pirch, N., Wissenbach, K., & Schrage, J. Investigation on reducing distortion by preheating during manufacture of aluminum components using selective laser melting. Journal of Laser Applications, 2014. 26(1), 012004.
16. Thijs, L., Verhaeghe, F., Craeghs, T., Van Humbeeck, J., & Kruth, J. P. A study of the microstructural evolution during selective laser melting of Ti–6Al–4V. Acta Materialia, 2010. 58(9), 3303–3312.
17. Kempen, K., Thijs, L., Van Humbeeck, J., & Kruth, J. P. Mechanical properties of AlSi10Mg produced by selective laser melting. Physics Procedia, 2012. 39, 439–446.
18. Brandl, E., Heckenberger, U., Holzinger, V., & Buchbinder, D. Additive manufactured AlSi10Mg samples using selective laser melting (SLM): Microstructure, high cycle fatigue, and fracture behavior. Materials & Design, 2012. 34, 159–169.
19. Rosenthal, I., Stern, A., & Frage, N. Microstructure and mechanical properties of AlSi10Mg parts produced by the laser beam additive manufacturing (AM) technology. Metallurgical and Materials Transactions A, 2014. 45(6), 2569–2579.
20. Tang, M., Pistorius, P. C., & Beuth, J. L. Prediction of lack-of-fusion porosity for powder bed fusion. Additive Manufacturing, 2017. 14, 39–48.
21. Rometsch, P. A., Zhu, Y., Wu, X., & Huang, A. Additive manufacturing of aluminum alloys. Advanced Engineering Materials, 2019. 21(9), 1801218.
22. Read, N., Wang, W., Essa, K., & Attallah, M. M. Selective laser melting of AlSi10Mg alloy: Process optimisation and mechanical properties development. Materials & Design, 2015. 65, 417–424.
23. Uzan, N. E., Shneck, R., Yeheskel, O., & Frage, N. Fatigue of additive manufactured AlSi10Mg specimens under rotating bending. International Journal of Fatigue, 2018. 116, 257–268.
24. Mertens, R., et al. Mechanical properties of aluminium alloys produced by selective laser melting. Procedia CIRP, 2014. 21, 244–249.
25. Ye H. An overview of the development of Al-Si-alloy based material for engine applications. J Mater Eng Perform 2003. 12, 288–97. https://doi.org/10.1361/ 105994903770343132.
26. Chowdhury, S., N., Chander Prakash, Y., Ramakrishna, S., Dixit, S., Gupta, L. R., Buddhi, D., (2022). Laser powder bed fusion: a state-of-the-art review of the technology, materials, properties & defects, and numerical modelling, Journal of Materials Research and Technology, V, 20, P. 2109. 2172, https://doi.org/10.1016/j.jmrt.2022.07.121.
27. Zhao L, Song L, Santos Macías JG, Zhu Y, Huang M, Simar A, et al. Review on the correlation between microstructure and mechanical performance for laser powder bed fusion AlSi10Mg. Addit Manuf 2022;56:102914. https://doi.org/10.1016/j. addma.2022.102914. [10] Jandaghi MR, Aversa A, Manfredi D, Calignano F, Lavagna L,
28. Pavese M. In situ alloying of AlSi10Mg-5 wt% Ni through laser powder bed fusion and subsequent heat treatment. J Alloys Compd 2022. 904:164081. https://doi.org/10.1016/j. jallcom.2022.164081.
29. C. Kammer, C. Kammer, Aluminium Handbook, Aluminium-Verlag Marketing &Kommunikation GmbH, Germany, 1999. 61–73, 1999.
30. Cho, K. T., Nunez, L., Shelton, J., & Sciammarella, F. Investigation of Effect of Processing Parameters for Direct Energy Deposition Additive Manufacturing Technologies. Journal of Manufacturing and Materials Processing, 2023. 7(3), 105. https://doi.org/10.3390/jmmp7030105
31. Weiming Ji, Runhua Zhou, Priyanka Vivegananthan, Mao See Wu, Huajian Gao, Kun Zhou, Recent progress in gradient-structured metals and alloys, Progress in Materials Science,Volume 140, 2023. 101194, https://doi.org/10.1016/j.pmatsci.2023.101194.
32. Nagareddy Gadlegaonkar, Premendra J. Bansod, Avinash Lakshmikanthan and Krishnakant Bhole, A Review on Additively Manufactured AlSi10Mg Alloy: Mechanical, Tribological, and Microstructure Properties, Journal of Mines, Metals and Fuels, 2025. 73(1): 87-101; 2025. DOI: 10.18311/jmmf/2025/46621.
33. Pal, R., & Basak, A. Linking Powder Properties, Printing Parameters, Post-Processing Methods, and Fatigue Properties in Additive Manufacturing of AlSi10Mg. Alloys, 2022. 1(2), 149-179. https://doi.org/10.3390/alloys1020010
34. Hasso Weiland, Anthony D. Rollett, William A. Cassada., ICAA13: 13th International Conference on Aluminum Alloys: 13th International Conference on Aluminum Alloys First published:5 June 2012. Online ISBN:9781118495292 |DOI:10.1002/9781118495292
35. Murat AKTÜRK, Mehmet Erdi KORKMAZ, A Review on Determining the Material Structural Parameters of Aluminum Alloys Produced by Additive Manufacturing Method, Manufacturing Technologies and Applications Vol: 2, Issue: 1, 2021. (49-60)
36. Tonolini, P., Montesano, L., Tocci, M., Pola, A. and Gelfi, M. Wear Behavior of AlSi10Mg Alloy Produced by Laser-Based Powder Bed Fusion and Gravity Casting. Adv. Eng. Mater., 2021. 23: 2100147. https://doi.org/10.1002/adem.202100147