Fabrication of Al-11.2Si Components by Direct Laser Metal Deposition for Automotive Applications

다국어 초록 (Multilingual Abstract)

Recently, Al-Si alloys samples have been manufactured at lab scale using various additive manufacturing processes, but so far there is no literature available to investigate the feasibility of fabricating Al-Si alloy component for automotive component applications using Direct Laser Metal Deposition (LMD) technique. This paper deals with the practical challenges of building single wall and block deposition (cuboid shapes) of eutectic Al-Si alloy using direct laser metal deposition process for developing automotive applications. Two scanning pattern, hatch pattern and single wall pattern were chosen to study the effect of scanning direction on mechanical properties as well as microstructural evolution. Microstructural investigation of single wall and block deposition using optical and scanning electron microscopy revealed a 99.9% dense component with very fine hypoeutectic microstructure. Tensile test sample extracted from block deposition showed an impressive elongation of 9% with an ultimate tensile strength of 225 MPa and tensile test sample of single wall showed an average elongation of 9.4% with an ultimate tensile strength of 225 MPa. This investigation revealed that direct laser metal deposition could successfully print the eutectic Al-Si alloy bracket on shock tower hood without any distortion or bending.

목차 (Table of Contents)

• Abstract
• 1. Introduction
• 2. Experimental procedures
• 3. Results and Discussion
• 4. Conclusion
• Acknowledgement
• References

참고문헌 (Reference)

1 Wang, X.J., "The effect of atmosphere on the structure and properties of a selective laser melted Al–12Si alloy" 597 : 370-375, 2014

2 Mazumder, J., "The direct metal deposition of H13 tool steel for 3-D components" 49 (49): 55-60, 1997

3 Kang, N., "Microstructure and strength analysis of eutectic Al-Si alloy in-situ manufactured using selective laser melting from elemental powder mixture" 691 : 316-322, 2017

4 Mathew, R., "Microstructural refinement of aluminium-zinc-silicon coated steels" 2016

5 Dinda, G.P, "Microstructural Characterization of Laser-Deposited Al 4047 Alloy" 44 (44): 2233-2242, 2012

6 Olatunde Olakanmi, E., "Laser sintering of blended Al‐Si powders" 18 (18): 109-119, 2012

7 Dinda, G.P., "Laser aided direct metal deposition of Inconel 625 superalloy, Microstructural evolution and thermal stability" 509 (509): 98-104, 2009

8 Thijs, L., "Fine-structured aluminium products with controllable texture by selective laser melting of pre-alloyed AlSi10Mg powder" 61 (61): 1809-1819, 2013

9 Dinda, G.P, "Fabrication of Ti-6Al-4V scaffolds by direct metal deposition, Metallurgical and Materials Transactions A" 39 (39): 2914-2922, 2008

10 Dinda, G.P, "Evolution of microstructure in laser deposited Al–11.28%Si alloy" 206 (206): 2152-2160, 2012

11 Nahmany, M, "Electron beam welding of AlSi10Mg workpieces produced by selected laser melting additive manufacturing technology" 8 : 63-70, 2015

12 Simchi, A., "Direct laser sintering of metal powders, Mechanism, kinetics and microstructural features" 428 (428): 148-158, 2006

13 Prashanth, K.G, "Defining the tensile properties of Al-12Si parts produced by selective laser melting" 126 : 25-35, 2017

14 Zhuang, W, "Deep surface rolling for fatigue life enhancement of laser clad aircraft aluminium alloy" 320 : 558-562, 2014

15 Mazumder, J., "Closed loop direct metal deposition, Art to Part" 34 (34): 397-414, 2000

16 Chou, R., "Additive Manufacturing of Al-12Si Alloy Via Pulsed Selective Laser Melting" 67 (67): 590-596, 2015

17 Li, X.P, "A selective laser melting and solution heat treatment refined Al–12Si alloy with a controllable ultrafine eutectic microstructure and 25% tensile ductility" 95 : 74-82, 2015