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High and very high cycle fatigue failure mechanisms in selective laser melted aluminum alloys

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Abstract

Selective laser melting, a laser-based additive manufacturing process, can manufacture components with good geometrical integrity. Application of the selective laser melting process for serial production is subject to its reliability on mechanical properties, especially on fatigue behavior, when it is required to be applied for dynamic applications. This study focuses on microstructural, quasistatic, high cycle fatigue (HCF), and very high cycle fatigue (VHCF) mechanisms of aluminum alloys manufactured by selective laser melting. Manufacturing of hybrid structures by selective laser melting process is also investigated. Microstructural features were investigated for process-induced effects and the corresponding influence on quasistatic and fatigue properties. The microstructural features can be controlled in the selective laser melting process for required properties. Joining strengths in hybrid structures can be improved by post process heat-treatments. Material constants in different fatigue regions were determined, and higher fatigue strength of hybrid alloys was achieved in HCF as well as VHCF regimes.

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ACKNOWLEDGMENTS

The authors would like to acknowledge Eric Wycisk and Claus Emmelmann from Institute of Laser and System Technologies (iLAS), Technical University Hamburg-Harburg (TUHH) regarding their excellent cooperation in manufacturing of investigated specimens.

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Authors and Affiliations

  1. Department of Materials Test Engineering (WPT), TU Dortmund University, Dortmund, 44227, Germany

    Shafaqat Siddique, Mustafa Awd, Jochen Tenkamp & Frank Walther

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  1. Shafaqat Siddique
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  2. Mustafa Awd
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  3. Jochen Tenkamp
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  4. Frank Walther
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Correspondence to Mustafa Awd.

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Siddique, S., Awd, M., Tenkamp, J. et al. High and very high cycle fatigue failure mechanisms in selective laser melted aluminum alloys. Journal of Materials Research 32, 4296–4304 (2017). https://doi.org/10.1557/jmr.2017.314

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  • DOI: https://doi.org/10.1557/jmr.2017.314

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