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Article

Simulation of Cyclic Deformation Behavior of Selective Laser Melted and Hybrid-Manufactured Aluminum Alloys Using the Phase-Field Method

1
Department of Materials Test Engineering (WPT), TU Dortmund University, 44227 Dortmund, Germany
2
Institute of Mechanics (IOM), TU Dortmund University, 44227 Dortmund, Germany
*
Author to whom correspondence should be addressed.
Appl. Sci. 2018, 8(10), 1948; https://doi.org/10.3390/app8101948
Received: 2 October 2018 / Revised: 11 October 2018 / Accepted: 11 October 2018 / Published: 16 October 2018
(This article belongs to the Special Issue Fatigue Damage of Additively Manufactured Parts)
Selective laser melting process has already been developed for many metallic materials, including steel, aluminum, and titanium. The quasistatic properties of these materials have been found to be comparable or even better than their conventionally-manufactured counterparts; however, for their reliable applications in operational components, their fatigue behavior plays a critical role, which is dominated by several process-related features, like surface roughness, remnant porosity, microstructure, and residual stresses, which are controlled by the processing features, like imparted energy density to the material, its corresponding solidification behavior, the cooling rate in the process, as well as post-processing treatments. This study investigates the influence of these parameters on the cyclic deformation behavior of selective laser melted as well as hybrid-manufactured aluminum alloys. The corresponding microstructural features and porosity conditions are evaluated for developing correlations between the process conditions to microstructure, the deformation behavior, and the corresponding fatigue lives. From the numerical point of view, damage development with respect to process-induced cyclic deformation behavior is assessed by the phase-field method, which has been identified as an appropriate method for the determination of fatigue life at the respective applied stress levels. Fatigue strength of SLM-processed parts is found better than their cast counterparts, while hybridization has further increased fatigue strength. No effect of test frequency on the fatigue life could be established. View Full-Text
Keywords: selective laser melting; Al-alloys; porosity; residual stresses; deformation behavior; phase-field method selective laser melting; Al-alloys; porosity; residual stresses; deformation behavior; phase-field method
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MDPI and ACS Style

Siddique, S.; Awd, M.; Wiegold, T.; Klinge, S.; Walther, F. Simulation of Cyclic Deformation Behavior of Selective Laser Melted and Hybrid-Manufactured Aluminum Alloys Using the Phase-Field Method. Appl. Sci. 2018, 8, 1948. https://doi.org/10.3390/app8101948

AMA Style

Siddique S, Awd M, Wiegold T, Klinge S, Walther F. Simulation of Cyclic Deformation Behavior of Selective Laser Melted and Hybrid-Manufactured Aluminum Alloys Using the Phase-Field Method. Applied Sciences. 2018; 8(10):1948. https://doi.org/10.3390/app8101948

Chicago/Turabian Style

Siddique, Shafaqat, Mustafa Awd, Tillmann Wiegold, Sandra Klinge, and Frank Walther. 2018. "Simulation of Cyclic Deformation Behavior of Selective Laser Melted and Hybrid-Manufactured Aluminum Alloys Using the Phase-Field Method" Applied Sciences 8, no. 10: 1948. https://doi.org/10.3390/app8101948

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