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Open AccessFeature PaperArticle

Effect of Surface and Subsurface Defects on Fatigue Behavior of AlSi10Mg Alloy Processed by Laser Powder Bed Fusion (L-PBF)

1
Department of Mechanical Engineering, Politecnico di Milano, 20156 Milan, Italy
2
Rosler Italiana Srl, 20863 Concorezzo, Italy
3
Department of Chemistry, Materials and Chemical Engineering, Politecnico di Milano, 20133 Milan, Italy
4
Aidro S.r.l, 21120 Taino, Italy
*
Author to whom correspondence should be addressed.
Metals 2019, 9(10), 1063; https://doi.org/10.3390/met9101063
Received: 28 August 2019 / Revised: 20 September 2019 / Accepted: 22 September 2019 / Published: 29 September 2019
The fatigue behaviour of an AlSi10Mg alloy processed by laser powder bed fusion (L-PBF) and subjected to different surface finishing processes was investigated paying special attention to the residual defects on the surface and the dominant fatigue failure mechanisms. Roughness measurements and qualitative surface morphology analysis showed smooth surfaces in the case of vibro-finishing and machining followed by polishing. The fatigue performance did not reveal to be directly related to surface roughness, but residual intrusions left on the finished surfaces. Post-mortem analysis showed single- or multiple-crack nucleation from pores opened on the surface, un-melted powders, or spatters considered as typical L-PBF defects. A fatigue limit of 195 MPa for machined and polished samples was obtained by substantial removal of surface and subsurface defects. View Full-Text
Keywords: AlSi10Mg alloy; laser powder bed fusion; fatigue strength; surface finishing; surface texture AlSi10Mg alloy; laser powder bed fusion; fatigue strength; surface finishing; surface texture
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MDPI and ACS Style

Hamidi Nasab, M.; Giussani, A.; Gastaldi, D.; Tirelli, V.; Vedani, M. Effect of Surface and Subsurface Defects on Fatigue Behavior of AlSi10Mg Alloy Processed by Laser Powder Bed Fusion (L-PBF). Metals 2019, 9, 1063.

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