Fatigue performance of TPMS-based AlSi10Mg architected cellular materials fabricated via hybrid and powder bed fusion methods

IF 5.7 2区材料科学 Q1 ENGINEERING, MECHANICAL

International Journal of Fatigue Pub Date : 2024-12-05 DOI:10.1016/j.ijfatigue.2024.108758

Agyapal Singh , Abdulrahman Jaber , Nikolaos Karathanasopoulos

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Abstract

This work investigates the fatigue performance of AlSi10Mg-based architected materials fabricated using hybrid manufacturing and powder bed fusion (PBF) methods. For the analysis, cellular materials with triply periodic minimal surface (TPMS) topologies, including Gyroid and IWP architectures are manufactured and subject to load-controlled, compression-compression, cyclic loading. Quantitative fatigue performance comparisons of hybrid manufactured (cast) with PBF as-built (PBF-AB) and heat-treated (PBF-HT) samples are performed. Cast samples exhibit the highest fatigue rigidity, and resistance to permanent deformation and fatigue damage, followed by PBF-HT samples, with PBF-AB samples yielding the shortest fatigue life. Gyroid 30 % samples consistently outperform Gyroid 20 % and IWP 30 % designs. The dependence of the fatigue performance of PBF-HT samples on the loading frequency and directionality are investigated, with lower loading frequencies and out-of-building plane loads resulting in a significant accumulation of fatigue ratcheting and fatigue damage strains, respectively. The post-fatigue analysis of the quasi-static stress–strain behavior confirms that cast samples maintain high structural integrity, and a low degradation of mechanical properties over a large number of loading cycles. The analysis provides benchmark results on the process-structure-property relationship of advanced AlSi10Mg materials as a function of their manufacturing method and cyclic loading performance.

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混合和粉末床熔合制备的基于tpms的AlSi10Mg结构蜂窝材料的疲劳性能

本文研究了采用混合制造和粉末床熔合（PBF）方法制备的alsi10mg基建筑材料的疲劳性能。为了进行分析，制造了具有三周期最小表面（TPMS）拓扑结构的细胞材料，包括Gyroid和IWP结构，并进行了负载控制、压缩压缩和循环加载。对混合制造（铸造）PBF成品（PBF- ab）和热处理（PBF- ht）样品进行了定量疲劳性能比较。铸态样品具有最高的疲劳刚度、抗永久变形和疲劳损伤能力，其次是PBF-HT样品，而PBF-AB样品的疲劳寿命最短。陀螺仪30%样品始终优于陀螺仪20%和IWP 30%的设计。研究了PBF-HT试样的疲劳性能与加载频率和方向性的关系，较低的加载频率和建筑外平面载荷分别导致疲劳棘轮应变和疲劳损伤应变的显著积累。准静态应力-应变行为的疲劳后分析证实，铸态样品在大量加载循环中保持了较高的结构完整性，并且力学性能的退化程度较低。该分析为先进AlSi10Mg材料的工艺-结构-性能关系及其制造方法和循环加载性能提供了基准结果。

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来源期刊

International Journal of Fatigue 工程技术-材料科学：综合

CiteScore

10.70

自引率

21.70%

发文量

619

审稿时长

58 days

期刊介绍： Typical subjects discussed in International Journal of Fatigue address: Novel fatigue testing and characterization methods (new kinds of fatigue tests, critical evaluation of existing methods, in situ measurement of fatigue degradation, non-contact field measurements) Multiaxial fatigue and complex loading effects of materials and structures, exploring state-of-the-art concepts in degradation under cyclic loading Fatigue in the very high cycle regime, including failure mode transitions from surface to subsurface, effects of surface treatment, processing, and loading conditions Modeling (including degradation processes and related driving forces, multiscale/multi-resolution methods, computational hierarchical and concurrent methods for coupled component and material responses, novel methods for notch root analysis, fracture mechanics, damage mechanics, crack growth kinetics, life prediction and durability, and prediction of stochastic fatigue behavior reflecting microstructure and service conditions) Models for early stages of fatigue crack formation and growth that explicitly consider microstructure and relevant materials science aspects Understanding the influence or manufacturing and processing route on fatigue degradation, and embedding this understanding in more predictive schemes for mitigation and design against fatigue Prognosis and damage state awareness (including sensors, monitoring, methodology, interactive control, accelerated methods, data interpretation) Applications of technologies associated with fatigue and their implications for structural integrity and reliability. This includes issues related to design, operation and maintenance, i.e., life cycle engineering Smart materials and structures that can sense and mitigate fatigue degradation Fatigue of devices and structures at small scales, including effects of process route and surfaces/interfaces.