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High-temperature tensile behavior of AlSi7Mg parts built by LPBF under high-productivity conditions

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Abstract

As additive manufacturing of metals gains traction for demanding applications, more comprehensive material cards covering mechanical response across a broader spectrum of operating conditions are needed. The integration of additive manufacturing into industries that rely on aluminum alloys, notably automotive and aerospace, underscores the imperative of a profound comprehension of how these materials respond to mechanical loading at elevated temperatures. Such insights are not only important for powertrain components but also for parts that combine structural and functional purposes, such as heat exchangers. At the same time, automotive applications need to target the production of large parts with sufficiently high productivity. This study addresses the intricate interplay between microstructural evolution, plastic deformation and mechanical response of AlSi7Mg parts fabricated by laser powder bed fusion under high-productivity conditions, spanning a testing temperature range of 25–300 °C. Above 150 °C, a significant decrease in proof and tensile strength is measured, accompanied by localized necking and the formation of dimples on the rupture surfaces. At 300 °C, the pronounced plasticization leads to yielding and failure at stress values 30–40% lower than at room temperature, with triple ductility. Work-hardening coefficients were calculated to describe the plastic regime. Furthermore, an investigation into density, hardness, microstructure, and fracture surfaces was conducted to corroborate the mechanical response. The outcomes enabled the quantification of mechanical property variations across the 6 temperature intervals, thereby constructing a map that empowers industry to unlock the full potential of additive manufacturing aluminum alloys.

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Acknowledgments

This study was carried out within the framework of the PIANO NAZIONALE DI RIPRESA E RESILIENZA (PNRR)—MISSION 4 COMPONENT 2, “From research to business” INVESTMENT 1.4, Strengthening research structures and creation of “national R&D champions” on some Keys Enabling Technologies, financed by the European Union—NextGenerationEU—Project identified with code CN00000023—CUP E93C22001070001. Title “Sustainable Mobility Center (Centro Nazionale per la Mobilità Sostenibile—CNMS)”—Spoke 12—Communication MUR 3138/2021 amended with DD 3175/2021.

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  1. Department of Engineering “Enzo Ferrari” (DIEF), University of Modena and Reggio Emilia, 41125, Modena, MO, Italy

    Elena Bassoli, Emanuele Tognoli & Silvio Defanti

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  1. Elena Bassoli
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  2. Emanuele Tognoli
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Contributions

Conceptualization: Elena Bassoli; methodology: Elena Bassoli, Emanuele Tognoli; validation: Emanuele Tognoli, Silvio Defanti; formal analysis: Emanuele Tognoli, Silvio Defanti; Investigation: Emanuele Tognoli, Silvio Defanti; data curation: Emanuele Tognoli, Silvio Defanti; writing—original draft: Emanuele Tognoli; Writing—review and editing: Elena Bassoli, Silvio Defanti; Supervision: Elena Bassoli; visualization: Emanuele Tognoli, Silvio Defanti; resources: Elena Bassoli.

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Correspondence to Emanuele Tognoli.

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Bassoli, E., Tognoli, E. & Defanti, S. High-temperature tensile behavior of AlSi7Mg parts built by LPBF under high-productivity conditions. Prog Addit Manuf (2024). https://doi.org/10.1007/s40964-024-00590-4

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