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Influence of LPBF-Surface Characteristics on Fatigue Properties of Scalmalloy®

Center for Engineering Materials, State Materials Testing Institute Darmstadt (MPA) Chair, Institute für Materials Technology (IfW), Technical University of Darmstadt, Grafenstraße 2, 64293 Darmstadt, Germany
Institute of Production Management, Technology and Machine Tools (PTW), Technical University of Darmstadt, Otto-Berndt-Straße 2, 64287 Darmstadt, Germany
Author to whom correspondence should be addressed.
Academic Editor: Marco Mandolini
Metals 2021, 11(12), 1961;
Received: 27 October 2021 / Revised: 26 November 2021 / Accepted: 29 November 2021 / Published: 6 December 2021
(This article belongs to the Topic Additive Manufacturing)
Laser powder bed fusion (LPBF) has indisputable advantages when designing new components with complex geometries due to toolless manufacturing and the ability to manufacture components with undercuts. However, fatigue properties rely heavily on the surface condition. In this work, in-process surface parameters (three differing contour parameter sets) and post-process surface treatments, namely turning and shot peening, are varied to investigate the influence of each treatment on the resulting fatigue properties of LPBF-manufactured specimens of the aluminium–magnesium–scandium alloy Scalmalloy®. Therefore, metallographic analysis and surface roughness measurements, as well as residual stress measurements, computer tomography measurements, SEM-analyses, tensile and fatigue tests, along with fracture surface analysis, were performed. Despite the fact that newly developed in-process contour parameters are able to reduce the surface roughness significantly, only a minor improvement in fatigue properties could be observed: Crack initiation is caused by sharp, microscopic notches at the surface in combination with high tensile residual stresses at the surface, which are present on all in-process contour parameter specimens. Specimens using contour parameters with high line energy show keyhole pores localized in the subsurface area, which have no effect on crack initiation. Contours with low line energy have a slightly positive effect on fatigue strength because less pores can be found at the surface and subsurface area, which even more greatly promotes an early crack initiation. The post-process parameter sets, turning and shot peening, both improve fatigue behaviour significantly: Turned specimens show lowest surface roughness, while, for shot peened specimens, the tensile residual stresses of the surface radially shifted from the surface towards the centre of the specimens, which counteracts the crack initiation at the surface. View Full-Text
Keywords: fatigue; aluminium alloys; stress measurements; post processing; laser powder bed fusion fatigue; aluminium alloys; stress measurements; post processing; laser powder bed fusion
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MDPI and ACS Style

Musekamp, J.; Reiber, T.; Hoche, H.C.; Oechsner, M.; Weigold, M.; Abele, E. Influence of LPBF-Surface Characteristics on Fatigue Properties of Scalmalloy®. Metals 2021, 11, 1961.

AMA Style

Musekamp J, Reiber T, Hoche HC, Oechsner M, Weigold M, Abele E. Influence of LPBF-Surface Characteristics on Fatigue Properties of Scalmalloy®. Metals. 2021; 11(12):1961.

Chicago/Turabian Style

Musekamp, Jens, Thorsten Reiber, Holger Claus Hoche, Matthias Oechsner, Matthias Weigold, and Eberhard Abele. 2021. "Influence of LPBF-Surface Characteristics on Fatigue Properties of Scalmalloy®" Metals 11, no. 12: 1961.

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