Transient fatigue crack growth behaviour of additively manufactured AlSi10Mg aluminium alloy under various post-processing treatments

IF 5.7 2区材料科学 Q1 ENGINEERING, MECHANICAL

International Journal of Fatigue Pub Date : 2025-05-13 DOI:10.1016/j.ijfatigue.2025.109064

Rui F. Fernandes , Joel S. Jesus , Luis P. Borrego , Mario Guagliano , Ricardo Branco , Ricardo Cláudio , José A.M. Ferreira , José D. Costa

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Abstract

This study investigates the transient fatigue crack growth (FCG) behaviour of AlSi10Mg aluminium alloy specimens produced by laser powder bed fusion and subjected to different post-processing treatments, including as-built, as-built shot-peened, stress-relieved, and stress-relieved shot-peened conditions. FCG tests were performed under constant amplitude (R = 0.05) and single tensile overload conditions, with overload ratios of 1.5, 2.0, and 2.5 applied at stress intensity factor ranges of 4, 7, and 9 MPa√m.

Shot peening had minimal influence on near-threshold FCG rates in as-built specimens, though it slightly increased the threshold value. At higher ΔK values, as-built and as-built shot-peened specimens exhibited similar FCG behaviour, while shot peening provide no additional FCG resistance in stress-relieved specimens. Overload-induced crack closure was strongly influenced by the magnitude of the overload ratio, with as-built specimens showing FCG retardation even under lower overload ratios (OLR = 1.5). In contrast, stress-relieved specimens exhibited minimal sensitivity to such conditions.

Higher overload ratios (OLR = 2.0 and 2.5) induced greater crack wake plasticity, resulting in pronounced crack retardation in both as-built and stress-relieved conditions. However, as-built specimens fractured under higher overload magnitudes, highlighting the superior ductility and toughness of stress-relieved specimens. Fracture surface analysis revealed plastic deformation mechanisms induced by overloads, confirming an enhanced crack closure after overload application.

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增材制造AlSi10Mg铝合金在不同后处理下的瞬态疲劳裂纹扩展行为

本研究研究了激光粉末床熔合生产的AlSi10Mg铝合金试样的瞬态疲劳裂纹扩展（FCG）行为，并进行了不同的后处理处理，包括建成、建成喷丸、去应力和去应力喷丸处理。FCG试验分别在恒幅（R = 0.05）和单张过载条件下进行，过载比分别为1.5、2.0和2.5，应力强度因子范围分别为4、7和9 MPa / m。喷丸强化对接近阈值的FCG率的影响最小，尽管它稍微增加了阈值。在较高的ΔK值下，建成和建成后喷丸处理的样品表现出相似的FCG行为，而喷丸处理在应力消除的样品中没有提供额外的FCG阻力。过载引起的裂纹闭合受过载比大小的强烈影响，即使在较低的过载比下（OLR = 1.5），已建试件也表现出FCG延迟。相反，应力解除的标本对这种条件表现出最小的敏感性。较高的过载比（OLR = 2.0和2.5）诱导了更大的裂纹尾迹塑性，导致在建造和解除应力条件下都有明显的裂纹延迟。然而，建成试样在较高的过载强度下发生断裂，这表明去应力试样具有较好的延性和韧性。断口表面分析揭示了超载引起的塑性变形机制，证实了超载后裂纹闭合的增强。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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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.