Skip to main content
SpringerLink
Log in

Mechanical behaviour of AlSi10Mg lattice structures manufactured by the Selective Laser Melting (SLM)

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Additive Manufacturing (AM), particularly Selective Laser Melting (SLM), has enabled design and production of complex metal lattice structures with specifically required properties, minimizing weight. The aim of this work is to provide insight into the influence of cell topology, cell size and beam diameter on deformation and failure behaviour of different SLM-manufactured AlSi10Mg alloy structures under static compressive loading. Design of experiment (DOE) analysis is performed to define geometrical features and dimensional characteristics of cell unit for specimen final configuration. A total of sixteen topological combinations was obtained, and forty-eight lattice specimens with three replicas for each cell type were manufactured with random order process to minimize manufacturing time variation and dependence. The full experimental testing results were analysed and compared in absolute terms and related to lattice density. Furthermore, a deep experimental microscopic analysis was conducted for a statistical analysis of representative beam diameters and real cell sizes for lattice samples. Additionally, micro-computed tomography (micro-CT) inspection was employed to analyse the local morphology and to characterize material distribution and in particular to verify defect presence (such as porosity and superficial anomalies) that may affect the mechanical behaviour.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
Fig. 26
Fig. 27
Fig. 28
Fig. 29
Fig. 30
Fig. 31
Fig. 32
Fig. 33
Fig. 34
Fig. 35
Fig. 36
Fig. 37
Fig. 38

Similar content being viewed by others

Data availability

Not applicable.

Code availability

Not applicable.

References

  1. Riva L, Ginestra PS, Elisabetta Ceretti E (2021) Mechanical characterization and properties of laser-based powder bed–fused lattice structures: a review. Int J Adv Manuf Technol 113:649–671. https://doi.org/10.1007/s00170-021-06631-4

    Article  Google Scholar 

  2. Thompson MK, Moroni G, Vaneker T, Fadel G, Campbell RI, Gibson I, Bernard A, Schulz J, Graf P, Ahuja B, Martina F (2016) Design for additive manufacturing: trends, opportunities, considerations, and constraints. CIRP Ann Manuf Technol 65:737–760. https://doi.org/10.1016/j.cirp.2016.05.004

    Article  Google Scholar 

  3. DebRoy T, Wei HL, Zuback JS, Mukherjee T, Elmer JW, Milewski JO, Beese AM, Wilson-Heid A, de A, Zhang W, (2018) Additive manufacturing of metallic components – process, structure and properties. Prog Mater Sci 92:112–224

    Article  Google Scholar 

  4. Yakout M, Elbestawi MA, Veldhuis SC (2018) A review of metal additive manufacturing technologies. Solid State Phenom 278:1–14

    Article  Google Scholar 

  5. Wohlers Associates (2010) What is additive manufacturing? https://wohlersassociates.com/additive-manufacturing.html

  6. Bhavar V, Kattire P, Patil V et al (2014) A review on powder bed fusion technology of metal additive manufacturing. In: 4th International conference and exhibition on Additive. CRC Press

  7. Rahman Rashid RA, Mallavarapu J, Palanisamy S et al (2017) A comparative study of flexural properties of additively manufactured aluminium lattice structures. Mater Today: Proc 4:8597–8604

    Google Scholar 

  8. Ginestra P, Ceretti E, Lobo D, Lowther M, Cruchley S, Kuehne S, Villapun V, Cox S, Grover L, Shepherd D, Attallah M, Addison O, Webber M (2020) Post processing of 3D printed metal scaffolds: a preliminary study of antimicrobial efficiency. Procedia Manuf 47:1106–1112

    Article  Google Scholar 

  9. Horn TJ, Harrysson OLA (2012) Overview of current additive manufacturing technologies and selected applications”. Sci Prog 95(3):255–282. https://doi.org/10.3184/003685012X13420984463047

    Article  Google Scholar 

  10. Calignano F et al (2017) Overview on additive manufacturing technologies,". Proc IEEE 105(4):593–612. https://doi.org/10.1109/JPROC.2016.2625098

    Article  Google Scholar 

  11. Panella FW, Pirinu A, Saponaro A, Santoro M (2022) Mechanical and fatigue behaviour of Sandwich elements with ABS core cells and GFRP plies, as function of cellular geometry and process parameters. IOP Conference Series: Mater Sci Eng 1214:012010. https://doi.org/10.1088/1757-899X/1214/1/012010

    Article  Google Scholar 

  12. Leary M, Mazur M, Elambasseril J, McMillan M, Chirent T, Sun Y, Qian M, Easton M, Brandt M (2016) Selective laser melting (SLM) of AlSi12Mg lattice structures. Mater Des 98:344–357

    Article  Google Scholar 

  13. Ashby MF (2005) Cellular ceramics. Wiley-VCH Verlag GmbH & Co. KGa A, Weinheim, FRG

    Google Scholar 

  14. Wieding J, Wolf A, Bader R (2014) Numerical optimization of open-porous bone scaffold structures to match the elastic properties of human cortical bone. J J Mech Behav Biomed Mater 37:56–68. https://doi.org/10.1016/j.jmbbm.2014.05.002

    Article  Google Scholar 

  15. Maskery I, Aboulkhair NT, Aremu AO, Tuck CJ, Ashcroft IA, Wildman RD, Hague RJM (2016) A mechanical property evaluation of graded density Al-Si10-Mg lattice structures manufactured by selective laser melting. Mater Sci Eng A 670:264–274

    Article  Google Scholar 

  16. Rosenthal I, Stern A, Frage N (2017) Strain rate sensitivity and fracture mechanism of AlSi10Mg parts produced by selective laser melting”. Mater Sci Eng A 682:509–517

    Article  Google Scholar 

  17. Capek J, Machova M, Fousova M, Kubasek J, Vojtech D, Fojt J, Jablonska E, Lipov J, Ruml T (2016) Highly porous, low elastic modulus 316L stainless steel scaffold prepared by selective laser melting. Mater Sci Eng C Mater Biol Appl 69:631–639

    Article  Google Scholar 

  18. Biffi C, Fiocchi J, Tuissi A (2018) Compounds, selective laser melting of AlSi10Mg: influence of process parameters on Mg2Si precipitation and Si spheroidization. J Alloy Compd 755:100–107. https://doi.org/10.1016/J.JALLCOM.2018.04.298

    Article  Google Scholar 

  19. Soltani N, Bahrami A, Pech-Canul MI (2013) The effect of Ti on mechanical properties of extruded in-situ Al-15 pct Mg 2 Si composite. Metall Mater Trans A 44:4366–4373. https://doi.org/10.1007/s11661-013-1747-2

    Article  Google Scholar 

  20. Soltani N, Nodooshan Jafari HR, Bahrami A, Pech-Canul MI, Liu W, Wu G (2014) Effect of hot extrusion on wear properties of Al–15wt.% Mg2Si in situ metal matrix composites. Mater Des 53:774–781. https://doi.org/10.1016/j.matdes.2013.07.084

    Article  Google Scholar 

  21. Capek J, Machova M, Fousova M, Kubasek J, Vojtech D, Fojt J, Jablonska E, Lipov J, Ruml T (2016) Highly porous, low elastic modulus 316L stainless steel scaffold prepared by selective laser melting”. Mater Sci Eng C Mater Biol Appl 69:631–639

    Article  Google Scholar 

  22. Brenne F, Niendorf T, Maier HJ (2013) Additively manufactured cellular structures: im- pact of microstructure and local strains on the monotonic and cyclic behavior under uniaxial and bending load. J Mater Process Technol 213:1558–1564

    Article  Google Scholar 

  23. Li P, Wang Z, Petrinic N, Siviour CR (2014) Deformation behaviour of stainless steel micro lattice structures by selective laser melting. Mater Sci Eng A 614:116–121

    Article  Google Scholar 

  24. Lebaal N, Zhang Y, Demoly F, Roth S, Gomes S, Bernard A (2019) Optimised lattice structure configuration for additive manufacturing. CIRP Ann Manuf Technol 68:117–120. https://doi.org/10.1016/j.cirp.2019.04.054

    Article  Google Scholar 

  25. Jayme D. Rossiter, Andrew A. Johnson, and Guy A. Bingham, 2020. Assessing the design and compressive performance of material extruded lattice structures. 3d Printing And Additive Manufacturing 7, 1. https://doi.org/10.1089/3dp.2019.003019.

  26. Ciccarese A, A. A. 2018/2019. Influenza dei parametri di processo sulle performance strutturali di soluzioni innovative ottenute mediante Additive Manufacturing. Master thesis in Tecnologia Meccanica II, University of Salento.

  27. Hazir E, Erdinler ES, Koc KH (2018) Optimization of CNC cutting parameters using design of experiment (DOE) and desirability function. J For Res 29:1423–1434. https://doi.org/10.1007/s11676-017-0555-8

    Article  Google Scholar 

  28. Araya-Calvo M, López-Gómez I, Chamberlain-Simonc N, León-Salazar JL, Guillén-Girón T, Corrales-Cordero JS, Sánchez-Brenes O (2018) Evaluation of compressive and flexural properties of continuous fiber fabrication additive manufacturing technology. Addit Manuf 22:157–164. https://doi.org/10.1016/j.addma.2018.05.007

    Article  Google Scholar 

  29. Maconachie T, Leary M, Lozanovski B, Zhang X, Qian M, Faruque O, Brand M (2019) SLM lattice structures: properties, performance, applications and challenges. Mater Des 183:108137. https://doi.org/10.1016/j.matdes.2019.108137

    Article  Google Scholar 

  30. Leary M et al (2016) Selective laser melting (SLM) of AlSi12Mg lattice structures. Mater Des 98:344–357

    Article  Google Scholar 

  31. Alghamdi A, Maconachie T, Downing D, Brandt M, Qian M, Leary M (2020) Effect of additive manufactured lattice defects on mechanical properties: an automated method for the enhancement of lattice geometry. Int J Adv Manuf Technol 108(3):1–15. https://doi.org/10.1007/s00170-020-05394-8

    Article  Google Scholar 

  32. Mazur M, Leary M, McMillan M, Sun S, Shidid D, Brandt M, 2017. 5 - Mechanical properties of Ti6Al4V and AlSi12Mg lattice structures manufactured by selective laser melting (SLM). Laser Additive Manufacturing, Materials, Design, Technologies, and Applications, Woodhead Publishing Series in Electronic and Optical Materials, 119–161. https://doi.org/10.1016/B978-0-08-100433-3.00005-1.

  33. Zhang D, Sun S, Qiu D, Gibson MA, Dargusch MS, Brandt M, Qian M, Easton M (2018) Metal alloys for fusion-based additive manufacturing. Adv Eng Mater 20(5):1700952

    Article  Google Scholar 

  34. Biana H, Aoyagia K, Zhaob Y, Maedac C, Mouric T, Chiba A (2020) Microstructure refinement for superior ductility of Al–Si alloy by electron beam melting. Addit Manuf 32:100982

    Google Scholar 

  35. Merino J, Ruvalcaba B, Varela J, Edel Arrieta LE, Murr RB, Wicker M, Benedict FM (2021). Multiple, comparative heat treatment and aging schedules for controlling the microstructures and mechanical properties of laser powder bed fusion fabricated AlSi10Mg alloy. J Market Res 13:669–685. https://doi.org/10.1016/j.jmrt.2021.04.062

    Article  Google Scholar 

  36. Taufik M, Jain PK (2013) Role of build orientation in layered manufacturing: a review. Int J Manuf Technol Manage 27(1–3):47–73

    Article  Google Scholar 

  37. Zhang Y, Bernard A, Gupta RK, Harik R (2016) Feature based building orientation optimisation for additive manufacturing. Rapid Prototyping Journal 22(2):358–376

    Article  Google Scholar 

  38. Qin Y, Qi Q, Scott PJ, Jiang X (2019) Determination of optimal build orientation for additive manufacturing using Muirhead mean and prioritised average operators. J Intell Manuf 30:3015–3034. https://doi.org/10.1007/s10845-019-01497-6

    Article  Google Scholar 

  39. Kulkarni P, Marsan A, Dutta D (2000) A review of process planning techniques in layered manufacturing. Rapid Prototyping J 6(1):18–35

    Article  Google Scholar 

  40. Zhang Y, Harik R, Fadel G, Bernard A (2018) A statistical method for build orientation determination in additive manufacturing. Rapid Prototyping J 25(1):187–207

    Article  Google Scholar 

  41. Gao W, Zhang Y, Ramanujan D, Ramani K, Chen Y, Williams CB, Wange CCL, Shina YC, Zhang S, Zavattierif P (2015) The status, challenges, and future of additive manufacturing in engineering. Comput Aided Des 69:65–89

    Article  Google Scholar 

  42. Goethals W, Heyndrickx M and Boone M, 2020. Fast tomographic inspection of cylindrical objects. J Nondestruct Eval 39 (76). https://doi.org/10.1007/s10921-020-00711-3.

  43. De Chiffre L, Carmignato S, Kruth JP, Schmitt R, Weckenmann A (2014) Industrial applications of computed tomography. CIRP Ann Manuf Technol 63(2):655–677. https://doi.org/10.1016/j.cirp.2014.05.011

    Article  Google Scholar 

  44. Ritman EL (2011) Current status of developments and applications of micro-CT. Annu Rev Biomed Eng 13:531–552. https://doi.org/10.1146/annurev-bioeng-071910-124717

    Article  Google Scholar 

  45. Plessis A, le Roux SG, Waller J et al (2019) Laboratory X-ray tomography for metal additive manufacturing: round robin test. Addit Manuf 30:100837. https://doi.org/10.1016/j.addma.2019.100837

    Article  Google Scholar 

  46. Peng C, Tran P, Nguyen-Xuan H, Ferreir AJM (2019) Mechanical performance and fatigue life prediction of lattice structures: parametric computational approach. Elsevier, Composite Structures

    Google Scholar 

  47. Fidan S (2020) The use of micro-CT in materials science and aerospace engineering. In: Orhan K (ed) Micro-computed Tomography (micro-CT) in Medicine and Engineering. Springer, Cham. https://doi.org/10.1007/978-3-030-16641-0_16

    Chapter  Google Scholar 

  48. du Plessis A, Yadroitsev I, Yadroitsava I, Le Roux SG (2018) X-ray microcomputed tomography in additive manufacturing: a review of the current technology and applications 3D Print. Manuf, Addit. https://doi.org/10.1089/3dp.2018.0060

    Book  Google Scholar 

  49. du Plessis A, Sperling P, Beerlink A, Tshabalala L, Hoosain S, Mathe N, le Roux SG (2018) Standard method for microCT-based additive manufacturing quality control 1: porosity analysis. MethodsX. https://doi.org/10.1016/j.mex.2018.09.005

    Article  Google Scholar 

  50. Orhan K, de FariaVasconcelos K, Gaêta-Araujo H (2020) Artifacts in micro-CT. Micro-computed tomography (micro-CT) in medicine and engineering. Springer, Cham, pp 35–48. https://doi.org/10.1007/978-3-030-16641-0_4

    Chapter  Google Scholar 

  51. Ohnesorge B, Flohr T, Schwarz K, Heiken JP, Bae KT (2000) Efficient correction for CT image artifacts caused by objects extending outside the scan field of view. Med Phys 27(1):39–46. https://doi.org/10.1118/1.598855

    Article  Google Scholar 

  52. A. Buades, B. Coll, J-M. Morel, 2005. A non-local algorithm for image denoising, IEEE Computer Society Conference on Computer Vision and Pattern Recognition (CVPR'05) 2, 60 – 65. https://doi.org/10.1109/CVPR.2005.38.

  53. Beyer C, Figueroa D (2016) Design and analysis of lattice structures for additive manufacturing. Journal of Manufacturing Science and Engineering 138(12):121014.07. https://doi.org/10.1115/1.4033957

    Article  Google Scholar 

  54. Liu X, Wada T, Suzki A, Takata N, Kobashi M, Kato M (2021) Understanding and suppressing shear band formation in strut-based lattice structures manufactured by laser powder bed fusion. Mater Des 199:109416. https://doi.org/10.1016/j.matdes.2020.109416

    Article  Google Scholar 

Download references

Acknowledgements

The authors thank very much Maurizio Calabrese for his preliminary support, Davide Damico for his useful experimental support and the HB-Technology company of Taranto (Italy) for their material support.

Funding

This work has been supported by Ministry of Economic Development, Bando Horizon 2020—PON 2014/2020, Innovative Solutions for the quality and sustainability of ADDitive manufacturing processes – SIADD project.

Author information

Authors and Affiliations

  1. Department of Engineering for Innovation, University of Salento, Via Per Monteroni, 73100, Lecce (LE), Italy

    Alessandra Pirinu, Teresa Primo, Antonio Del Prete & Francesco Willem Panella

  2. ENEA - Division for Sustainable Materials, Research Centre of Brindisi, S.S.7 Appia Km 706, 72100, Brindisi, Italy

    Fabio De Pascalis

Authors
  1. Alessandra Pirinu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Teresa Primo
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Antonio Del Prete
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Francesco Willem Panella
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Fabio De Pascalis
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Teresa Primo.

Ethics declarations

Competing interests

The authors declare no competing interests.

Ethics approval

Not applicable.

Consent to participate

Not applicable.

Consent for publication

All authors have agreed to authorship, read, and approved the manuscript, and given consent for submission and subsequent publication of the manuscript. The authors guarantee that the contribution to the work has not been previously published elsewhere.

Additional information

Publisher's note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Pirinu, A., Primo, T., Del Prete, A. et al. Mechanical behaviour of AlSi10Mg lattice structures manufactured by the Selective Laser Melting (SLM). Int J Adv Manuf Technol 124, 1651–1680 (2023). https://doi.org/10.1007/s00170-022-10390-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-10390-1

Keywords

Search

Navigation