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选区激光熔化成形AlSi10Mg合金工艺优化及传统铸造合金高周疲劳行为的对比研究

Research on Process Optimization of Selective Laser Melting Formed AlSi10Mg Alloy and Comparative Study on High-Cycle Fatigue Behavior with Traditional Casting Alloy

  • 摘要: AlSi10Mg合金是航空航天及汽车领域重要的轻质材料,传统铸造工艺形成的粗大组织及内部缺陷显著降低了该合金的强塑性及抗疲劳性能。本研究采用选区激光熔化(SLM)技术加工成形AlSi10Mg合金,通过优化SLM工艺参数制备出致密度超过99.5%、硬度达到130.87 HV的合金成形件,其抗拉强度、屈服强度和延伸率分别达到475.41MPa、297.66MPa、6.60%,并在此基础上开展了SLM成形AlSi10Mg合金高周疲劳断裂行为的研究。结果表明SLM成形AlSi10Mg合金由超细α-Al晶粒和连续的网状Si结构组成,其疲劳寿命显著优于传统铸造试样。在120 MPa应力水平下,传统铸造合金于941,123次循环后断裂,而SLM成形合金在10?次循环后仍未发生断裂。SLM成形合金中的超细组织与小尺度缺陷显著提高了材料的疲劳强度,抑制裂纹的萌生,同时SLM成形独特的网状Si结构促进疲劳裂纹发生偏转和分叉,有效降低裂纹扩展速率。本研究可为SLM成形AlSi10Mg合金在航空航天及汽车等高端领域的应用提供技术支撑。

     

    Abstract: AlSi10Mg alloy is an important lightweight material for aerospace and automotive applications. However, the coarse microstructure and internal defects associated with conventional casting significantly impair its strength, ductility, and fatigue resistance. In this study, AlSi10Mg alloy was fabricated by selective laser melting (SLM). By optimizing the SLM processing parameters, specimens with a relative density exceeding 99.5% and a hardness of 130.87 HV were obtained. The fabricated alloy exhibited ultimate tensile strength, yield strength, and elongation of 475.41 MPa: 297.66 MPa, and 6.60%, respectively. Furthermore, the high-cycle fatigue fracture behavior of SLM-fabricated AlSi10Mg alloy was systematically investigated. The results show that the SLM-fabricated alloy is composed of ultrafine α-Al grains and a continuous network-like Si structure, and exhibits a markedly longer fatigue life than its conventional cast counterpart. At a stress amplitude of 120 MPa, the conventional cast alloy fractured after 941,123 cycles, whereas the SLM-fabricated alloy remained unfailed even after 10? cycles. The enhanced fatigue performance is mainly attributed to the ultrafine microstructure and small-scale defects in the SLM-fabricated alloy, which improve fatigue strength and retard crack initiation. Meanwhile, the characteristic network-like Si structure promotes crack deflection and branching during fatigue crack propagation, thereby reducing the crack growth rate. This study provides technical support for the application of SLM-fabricated AlSi10Mg alloy in high-end fields such as aerospace and automotive engineering.

     

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