Novel integrated forming process for fabricating complex thin-walled AlSi10Mg alloy tubular parts via laser powder bed fusion and hot gas forming

IF 11.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING
Jiangkai Liang , Gaoning Tian , Quan Gao , Wei Du , Yanli Lin , Zhubin He
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引用次数: 0

Abstract

Currently, both additive manufacturing technologies and fluid pressure forming process face significant challenges in fabricating large-sized, complex thin-walled metal components. To address these challenges, this paper introduces a novel integrated forming process that utilizes laser powder bed fusion (LPBF) preforming and hot gas forming (HGF). This method employs LPBF technology to fabricate near-net-shape preforms, which are subsequently subjected to HGF treatment to realize micro-scale precise deformation. This study systematically investigates the performance of AlSi10Mg alloy thin-walled preforms prepared by LPBF, along with the characteristics of the formed parts following the HGF process. Furthermore, subsequent heat treatment protocols are employed to improve the microstructural properties of the formed parts. Compared to the direct LPBF technology, this method exhibits marked enhancements in dimensional accuracy and density of the fabricated parts, effectively controlling dimensional deviations and substantially reducing porosity. Ultimately, the process culminates in the fabrication of complex thin-walled AlSi10Mg alloy parts characterized by a superior microstructure and mechanical properties. Specifically, the formed parts, measuring 165 mm with a wall thickness of 1.2 mm, achieve a dimensional accuracy of ± 0.24 mm and a maximum wall thickness reduction rate of less than 14.2 %, while attaining an impressive density of 99.93 %. Additionally, the parts exhibit excellent uniformity concerning the distribution and morphology of the precipitated phases, along with the shape and structure of the grains. Following solution heat treatment, the formed parts exhibited tensile strengths of 282 MPa at room temperature and 186 MPa at 230 °C, accompanied by elongations of 15.9 % and 11.7 %, respectively. This favorable combination of strength and ductility renders these materials well-suited for engineering applications that demand high overall mechanical performance. However, aging heat treatment after solution treatment resulted in a significantly improved of the mechanical properties. The tensile strengths increased to 350 MPa at room temperature and 201 MPa at 230°C, while the elongations were concurrently reduced to 6.9 % and 10.1 %, respectively. Such a property profile makes these materials particularly suitable for specialized applications where high strength is prioritized over ductility. The feasibility of LPBF-prepared preforms via the subsequent HGF process was systematically confirmed, thereby establishing a foundational basis for the prospective application of this integrated forming methodology.
采用激光粉末床熔化和热成形相结合的方法制备复杂AlSi10Mg合金管状薄壁件
目前,无论是增材制造技术还是流体压力成形技术,都面临着制造大型、复杂薄壁金属部件的重大挑战。为了解决这些问题,本文介绍了一种利用激光粉末床熔合(LPBF)预成形和热气体成形(HGF)的新型集成成形工艺。该方法采用LPBF技术制备近净形状的预成形件,然后对预成形件进行HGF处理,实现微尺度的精确变形。本研究系统地研究了LPBF制备的AlSi10Mg合金薄壁预制件的性能,以及HGF工艺后成形件的特点。此外,采用后续热处理方案来改善成形零件的显微组织性能。与直接LPBF技术相比,该方法显著提高了零件的尺寸精度和密度,有效地控制了尺寸偏差,大大减少了孔隙率。最终,该工艺最终制造出具有优越微观结构和机械性能的复杂薄壁AlSi10Mg合金零件。具体而言,成形零件尺寸为165 mm,壁厚为1.2 mm,尺寸精度为±0.24 mm,最大壁厚减薄率小于14.2 %,同时获得99.93 %的令人印象深刻的密度。此外,这些零件在析出相的分布和形貌以及晶粒的形状和结构方面表现出极好的均匀性。固溶热处理后,成形件室温拉伸强度为282 MPa, 230℃拉伸强度为186 MPa,延伸率分别为15.9 %和11.7 %。这种强度和延展性的良好组合使这些材料非常适合要求高整体机械性能的工程应用。固溶处理后进行时效热处理,力学性能得到明显改善。室温拉伸强度为350 MPa, 230℃拉伸强度为201 MPa,伸长率分别降至6.9% %和10.1 %。这种特性使这些材料特别适合于高强度优先于延展性的特殊应用。系统地验证了通过后续HGF工艺制备lpbf预成形件的可行性,从而为该综合成形方法的前瞻性应用奠定了基础。
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
Additive manufacturing
Additive manufacturing Materials Science-General Materials Science
CiteScore
19.80
自引率
12.70%
发文量
648
审稿时长
35 days
期刊介绍: Additive Manufacturing stands as a peer-reviewed journal dedicated to delivering high-quality research papers and reviews in the field of additive manufacturing, serving both academia and industry leaders. The journal's objective is to recognize the innovative essence of additive manufacturing and its diverse applications, providing a comprehensive overview of current developments and future prospects. The transformative potential of additive manufacturing technologies in product design and manufacturing is poised to disrupt traditional approaches. In response to this paradigm shift, a distinctive and comprehensive publication outlet was essential. Additive Manufacturing fulfills this need, offering a platform for engineers, materials scientists, and practitioners across academia and various industries to document and share innovations in these evolving technologies.
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