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Abstract:
In this work, significant strength and ductility variations are reported for AlSi10Mg parts fabricated at different orientations using laser powder bed fusion (LPBF). Hardness and surface roughness of the specimens at different orientations were measured. Tensile testing together with digital image correlation technique were conducted on the specimens. XY specimens showed the highest yield stress and ultimate tensile strength while XZ specimens showed the highest ductility. Hardness measurements for different specimens were in accordance with the tensile test results, following the same order as the UTS values, XY specimens being the highest and XY-45° (out-of-plane) specimens being the lowest. Fractography of the broken surfaces of the specimens under tensile testing revealed the microstructural features and various defects in the tensile fracture. The anisotropy in mechanical properties is attributed to the microstructural anisotropy as well as presence of various types of defects induced by the AM process, which affects the deformation and failure mechanism of the parts. Linear relationships between experimental Vickers hardness versus yield stress and UTS measurements were developed. In case of material selection for different applications, these relationships can be used as a simple tool for converting hardness and yield stress (or UTS) values to each other. An equivalent strain-hardness relationship was also proposed which can be used for health monitoring of parts subject to tensile loading.

Keywords:
Laser powder bed fusion, Hardness, Mechanical properties, Defects, Microstructure