A new additive manufacturing factor dominating porosity and mechanical performance of alloys via laser powder bed fusion

IF 5.6 2区工程技术 Q1 ENGINEERING, MECHANICAL

Theoretical and Applied Fracture Mechanics Pub Date : 2025-10-13 DOI:10.1016/j.tafmec.2025.105288

Youshi Hong , Yu Xia , Aiguo Zhao

{"title":"A new additive manufacturing factor dominating porosity and mechanical performance of alloys via laser powder bed fusion","authors":"Youshi Hong , Yu Xia , Aiguo Zhao","doi":"10.1016/j.tafmec.2025.105288","DOIUrl":null,"url":null,"abstract":"<div><div>The mechanical behavior of additively manufactured (AMed) materials is basically attributed to the produced microstructure and porosity (or defects), which is the resultant of the additive manufacturing (AM) process with a set of processing parameters. In this paper, the effects of AM processing parameters on the mechanical behavior of AMed parts are comprehensively investigated. The data of porosity, tensile properties and fatigue strength in high-cycle and very-high-cycle regimes of AMed materials, such as titanium, aluminum and nickel alloys, as a function of laser volume energy density (Ev) are collected from our research and from the literature. Then, the variation of Ev with porosity, tensile properties and fatigue performance of AMed alloys is analyzed to evaluate the optimal or preferable range of the processing parameters in terms of Ev. Thus, a new dimensionless factor (FAM) of AM process is proposed, which aims to the characterization of AM process with the main target of resulted porosity and mechanical properties of high-cycle and very-high-cycle fatigue performance as well as tensile properties of AMed alloys. FAM is a dimensionless AM dominating factor that is a combination of Ev with intrinsic physical quantities of elastic modulus, shear modulus, magnitude of Burgers vector, staking fault energy, melting point and Boltzmann constant for related alloys. This factor is intended to be used in AM quality control for obtaining the lowest value of porosity and the highest values of fatigue strength and tensile properties of AMed alloys.</div></div>","PeriodicalId":22879,"journal":{"name":"Theoretical and Applied Fracture Mechanics","volume":"141 ","pages":"Article 105288"},"PeriodicalIF":5.6000,"publicationDate":"2025-10-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Theoretical and Applied Fracture Mechanics","FirstCategoryId":"5","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S016784422500446X","RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"ENGINEERING, MECHANICAL","Score":null,"Total":0}

引用次数: 0

Abstract

The mechanical behavior of additively manufactured (AMed) materials is basically attributed to the produced microstructure and porosity (or defects), which is the resultant of the additive manufacturing (AM) process with a set of processing parameters. In this paper, the effects of AM processing parameters on the mechanical behavior of AMed parts are comprehensively investigated. The data of porosity, tensile properties and fatigue strength in high-cycle and very-high-cycle regimes of AMed materials, such as titanium, aluminum and nickel alloys, as a function of laser volume energy density (E_v) are collected from our research and from the literature. Then, the variation of E_v with porosity, tensile properties and fatigue performance of AMed alloys is analyzed to evaluate the optimal or preferable range of the processing parameters in terms of E_v. Thus, a new dimensionless factor (F_AM) of AM process is proposed, which aims to the characterization of AM process with the main target of resulted porosity and mechanical properties of high-cycle and very-high-cycle fatigue performance as well as tensile properties of AMed alloys. F_AM is a dimensionless AM dominating factor that is a combination of E_v with intrinsic physical quantities of elastic modulus, shear modulus, magnitude of Burgers vector, staking fault energy, melting point and Boltzmann constant for related alloys. This factor is intended to be used in AM quality control for obtaining the lowest value of porosity and the highest values of fatigue strength and tensile properties of AMed alloys.

查看原文本刊更多论文

一种新的增材制造因素决定了激光粉末床熔合合金的孔隙率和力学性能

增材制造（AMed）材料的力学行为基本上归因于所产生的微观结构和孔隙率（或缺陷），这是具有一组加工参数的增材制造（AM）工艺的结果。本文全面研究了增材制造工艺参数对增材制造零件力学性能的影响。我们从研究和文献中收集了高周波和超高周波状态下的激光材料（如钛、铝和镍合金）的孔隙率、拉伸性能和疲劳强度与激光体积能量密度（Ev）的关系数据。然后，分析了电解电位随合金孔隙率、拉伸性能和疲劳性能的变化规律，以评价电解电位的最佳或较优加工参数范围。为此，提出了一种新的增材制造过程的无量纲因子（FAM），以增材制造过程的孔隙率、合金的高周、甚高周疲劳性能和拉伸性能为主要指标来表征增材制造过程。FAM是一个无量纲的AM主导因子，它是Ev与相关合金的固有物理量弹性模量、剪切模量、Burgers矢量大小、断层能、熔点和玻尔兹曼常数的组合。该系数旨在用于增材制造质量控制，以获得增材制造合金的最低孔隙率和最高疲劳强度和拉伸性能。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

求助全文

约1分钟内获得全文求助全文

来源期刊

Theoretical and Applied Fracture Mechanics 工程技术-工程：机械

CiteScore

8.40

自引率

18.90%

发文量

435

审稿时长

37 days

期刊介绍： Theoretical and Applied Fracture Mechanics'' aims & scopes have been re-designed to cover both the theoretical, applied, and numerical aspects associated with those cracking related phenomena taking place, at a micro-, meso-, and macroscopic level, in materials/components/structures of any kind. The journal aims to cover the cracking/mechanical behaviour of materials/components/structures in those situations involving both time-independent and time-dependent system of external forces/moments (such as, for instance, quasi-static, impulsive, impact, blasting, creep, contact, and fatigue loading). Since, under the above circumstances, the mechanical behaviour of cracked materials/components/structures is also affected by the environmental conditions, the journal would consider also those theoretical/experimental research works investigating the effect of external variables such as, for instance, the effect of corrosive environments as well as of high/low-temperature.