Abstract
Stir casting plays a major role in the production of Al-SiC10 % composites for aero space and automobile applications. However, obtaining the composites with homogenous distribution of the SiC particles, low porosity and without clustering of reinforcement particles are still a major problem faced by the research community. These kind of casting defects were overcome by the Additive Manufacturing (AM) technology. In this research, AlSi10Mg parts were manufactured by Laser-Powder Bed Fusion (LPBF) method, one of the AM techniques. The mechanical and morphological characteristics of Additive manufactured (AM) samples were compared with the Stir Casted (SC) samples. Both AM and SC samples were analyzed for the porosity% using the Optical Microscope (OM). From the porosity analysis, it was evident that the AM samples shows 14 % reduction in porosity when compared with the SC samples. Mechanical testing such as tensile test, hardness test, fracture toughness test and double shear stress were carried out. The results obtained from the tensile test reveals that the AM samples shows 28.6 % higher tensile strength than the SC samples. Similarly, the hardness test for the AM samples shows 23.69 % higher hardness strength than the SC samples. The fracture toughness test for the AM samples shows 50 % higher fracture toughness strength than the SC samples and from the results of double shear stress test proves that the AM samples shows 32.55 % higher shear stress than the SC samples. The outcome of this research proved that additive manufactured AlSi10Mg sample shows enhanced mechanical and morphological properties when compared with the conventional stir casting process.
Article PDF
Similar content being viewed by others
Explore related subjects
Discover the latest articles, news and stories from top researchers in related subjects.Avoid common mistakes on your manuscript.
Data Availability
The raw/processed data required to reproduce these findings cannot be shared at this time as the data also forms part of an ongoing study.
References
Salmi A, Piscopo G, Atzeni E, Minetola P, andIuliano L (2018) On the effect of part orientation on stress distribution in AlSi10Mg specimens fabricated by laser powder bed fusion (L-PBF). Procedia CIRP 67:191–196
Riemer A, Richard HA (2016) Crack propagation in additive manufactured materials and structures. Procedia Struct Integr 2:1229–1236
Almonti D, Baiocco G, Tagliaferri V, Ucciardello N (2020) Design and mechanical characterization of Voronoi structures manufactured by indirect additive manufacturing. Materials 13(5):1085
Casati R, Hamidi Nasab M, Coduri M, Tirelli V, Vedani M (2018) Effects of platform pre-heating and thermal-treatment strategies on properties of AlSi10Mg alloy processed by selective laser melting. Metals 8(11):954
Han Q, Gu H, Soe S, Setchi R, Lacan F, Hill J (2018) Manufacturability of AlSi10Mg overhang structures fabricated by laser powder bed fusion. Mater Des 160:1080–1095
Yu T, Hyer H, Sohn Y, Bai Y, Wu D (2019) Structure-property relationship in high strength and lightweight AlSi10Mgmicrolattices fabricated by selective laser melting. Mater Des 182:108062
Beevers E, Brandão AD, Gumpinger J, Gschweitl M, Seyfert C, Hofbauer P, … Ghidini T (2018) Fatigue properties and material characteristics of additively manufactured AlSi10Mg–Effect of the contour parameter on the microstructure, density, residual stress, roughness and mechanical properties. Int J Fatigue 117:148–162
Kan WH, Nadot Y, Foley M, Ridosz L, Proust G, Cairney JM (2019) Factors that affect the properties of additively-manufactured AlSi10Mg: Porosity versus microstructure. Addit Manuf 29:100805
Liu M, Takata N, Suzuki A, Kobashi M (2018) Microstructural characterization of cellular AlSi10Mg alloy fabricated by selective laser melting. Mater Des 157:478–491
Palumbo B, Del Re F, Martorelli M, Lanzotti A, Corrado P (2017) Tensile properties characterization of AlSi10Mg parts produced by direct metal laser sintering via nested effects modeling. Materials 10(2):144
Fousová M, Dvorský D, Michalcová A, Vojtěch D (2018) Changes in the microstructure and mechanical properties of additively manufactured AlSi10Mg alloy after exposure to elevated temperatures. Mater Charact 137:119–126
Read N, Wang W, Essa K, Attallah MM (2015) Selective laser melting of AlSi10Mg alloy: Process optimisation and mechanical properties development. Mater Des 65:417–424 (1980–2015)
Denti L (2018) Additive manufactured A357. 0 samples using the laser powder bed fusion technique: Shear and tensile performance. Metals 8(9):670
Dey D, Bhowmik A, Biswas A (2020) Effect of SiC content on mechanical and tribological properties of Al2024-SiC composites. Silicon: 1–11
Prabaharan T (2020) Mechanical and tribological characterization of stir cast AA6061 T6–SiC composite. Silicon :1–8
Surya MS, Prasanthi G (2021) Effect of SiC weight % on tribological characteristics of Al7075/SiC composites. Silicon :1–10
Karvanis K, Fasnakis D, Maropoulos A, Papanikolaou S (2016, November) Production and mechanical properties of Al-SiC metal matrix composites. In: IOP Conference Series: Materials Science and Engineering. IOP Publishing, Bristol, 161, 012070
Soltani S, Khosroshahi RA, Mousavian RT, Jiang ZY, Boostani AF, Brabazon D (2017) Stir casting process for manufacture of Al–SiC composites. Rare Met 36(7):581–590
Christy JV, Arunachalam R, Mourad AHI, Krishnan PK, Piya S, Al-Maharbi M (2020) Processing, properties, and microstructure of recycled aluminum alloy composites produced through an optimized stir and squeeze casting processes. J Manuf Process 59:287–301
Krishnan PK, Christy JV, Arunachalam R, Mourad AHI, Muraliraja R, Al-Maharbi M, ... Chandra MM (2019) Production of aluminum alloy-based metal matrix composites using scrap aluminum alloy and waste materials: Influence on microstructure and mechanical properties. J Alloys Compd 784:1047–1061
Kumar S, Vasumathi M (2020) Applying visualization techniques to study the fluid flow pattern and the particle distribution in the casting of metal matrix composites. J Manuf Process 58:668–676
Saravana kumar M, Begum SR, Vasumathi M (2019) Influence of stir casting parameters on particle distribution in metal matrix composites using stir casting process. Mater Res Express 6(10):1065d4
Casati R, Nasab MH, Vedani M (2018) Effect of different heat treatment routes on microstructure and mechanical properties of AlSi7Mg, AlSi10Mg and Al-Mg-Zr-Sc alloys produced by selective laser melting. In: Euro PM2018 Congress & Exhibition, pp 1–5
Girelli L, Tocci M, Gelfi M, Pola A (2019) Study of heat treatment parameters for additively manufactured AlSi10Mg in comparison with corresponding cast alloy. Mater Sci Eng A 739:317–328
Gouveia RM, Silva FJ, Atzeni E, Sormaz D, Alves JL, Pereira AB (2020) Effect of scan strategies and use of support structures on surface quality and hardness of L-PBF AlSi10Mg parts. Materials 13(10):2248
Somireddy M, Czekanski A (2017) Mechanical characterization of additively manufactured parts by FE modeling of mesostructure. J Manuf Mater Process 1(2):18
Leary M, Maconachie T, Sarker A, Faruque O, Brandt M (2019) Mechanical and thermal characterisation of AlSi10MgSLM block support structures. Mater Des 183:108138
Maamoun AH, Xue YF, Elbestawi MA, Veldhuis SC (2019) The effect of selective laser melting process parameters on the microstructure and mechanical properties of Al6061 and AlSi10Mg alloys. Materials 12(1):12
Zhang C, Zhu H, Qi Y, Zeng X (2019) The effect of annealing on microstructure and mechanical properties of selective laser melting AlSi10Mg. In: IOP Conference Series: Materials Science and Engineering, 538, 012023
Begum SR, Kumar MS, Pruncu CI, Vasumathi M, Harikrishnan P (2021) Optimization and fabrication of customized scaffold using additive manufacturing to match the property of human bone. J Mater Eng Perform, 1–12
Kumar MS, Pruncu CI, Harikrishnan P, Begum SR, Vasumathi M (2021) Experimental investigation of in-homogeneity in particle distribution during the processing of metal matrix composites. Silicon :1–13
Rajesh A, Santosh D (2017) Mechanical properties of Al-SiC metal matrix composites fabricated by stir casting route. Res Med Eng Sci 2(6):1–6
Akinwamide SO, Lemika SM, Abiodun B (2019) Study of microstructural and mechanical properties of stir cast Al (SiC-Mg-TiFe) composite. Fluid Dyn Mater Process 15(1):15–26
Bhaskar S, Kumar M, Patnaik A (2019) Mechanical and Tribological overview of ceramic particulates reinforced aluminium alloy composites. Rev Adv Mater Sci 58(1):280–294
Wang P, Lei H, Zhu X, Chen H, Fang D (2019) Influence of manufacturing geometric defects on the mechanical properties of AlSi10Mg alloy fabricated by selective laser melting. J Alloy Compd 789:852–859
Yan C, Hao L, Hussein A, Bubb SL, Young P, Raymont D (2014) Evaluation of light-weight AlSi10Mg periodic cellular lattice structures fabricated via direct metal laser sintering. J Mater Process Technol 214(4):856–864
Beretta S, Gargourimotlagh M, Foletti S, du Plessis A, Riccio M (2020) Fatigue strength assessment of “as built” AlSi10Mg manufactured by SLM with different build orientations. Int J Fatigue 139:105737
AlRedha S, Shterenlikht A, Mostafavi M, Van Gelderen D, Lopez-Botello OE, Reyes LA, … Garza C (2020) Effect of build orientation on fracture behaviour of AlSi10Mg produced by selective laser melting. Rapid Prototyp J 27(1):112–119
Subbiah R, Bensingh J, Kader A, Nayak S (2020) Influence of printing parameters on structures, mechanical properties and surface characterization of aluminium alloy manufactured using selective laser melting. Int J Adv Manuf Technol 106(11):5137–5147
Alghamdi F, Song X, Hadadzadeh A, Shalchi-Amirkhiz B, Mohammadi M, Haghshenas M (2020) Post heat treatment of additive manufactured AlSi10Mg: On silicon morphology, texture and small-scale properties. Mater Sci Eng A 783:139296
Yaghobizadeh O, Baharvandi HR, Ahmadi AR, Aghaei E (2019) Development of the properties of Al/SiC nano-composite fabricated by stir cast method by means of coating SiC particles with Al. Silicon 11(2):643–649
Sanjari M, Hadadzadeh A, Pirgazi H, Shahriari A, Amirkhiz BS, Kestens LA, Mohammadi M (2020) Selective laser melted stainless steel CX: Role of built orientation on microstructure and micro-mechanical properties. Mater Sci Eng A 786:139365
Del Re F, Scherillo F, Contaldi V, Palumbo B, Squillace A, Corrado P, Di Petta P (2019) Mechanical properties characterisation of AlSi10Mg parts produced by laser powder bed fusion additive manufacturing. Int J Mater Res 110(5):436–446
Kumar MS, Begum SR, Pruncu CI, Asl MS (2021) Role of homogeneous distribution of SiC reinforcement on the characteristics of stir casted Al–SiC composites. J Alloys Compd 869:159250
Hartunian P, Eshraghi M (2018) Effect of build orientation on the microstructure and mechanical properties of selective laser-melted Ti-6Al-4V alloy. J Manuf Mater Process 2(4):69
Premnath A (2020) Optimization of the process parameters on the mechanical and wear properties of Al-SiC nano-composites fabricated by friction stir processing using desirability approach. Silicon 12(3):665–675
Ponnusamy P, Rahman Rashid RA, Masood SH, Ruan D, Palanisamy S (2020) Mechanical properties of SLM-printed aluminium alloys. A review. Materials 13(19):4301
Dong M, Zhou W, Kamata K, Nomura N (2020) Microstructure and mechanical property of graphene oxide/AlSi10Mg composites fabricated by laser additive manufacturing. Mater Charact 170:110678
Kumar PV, Jebakani D, Velmurugan C, Senthilkumar V (2021) Effect of SiC on mechanical and microstructural characteristics of Al based functionally graded material. Silicon :1–6
Acknowledgements
Authors sincerely thanks to Mount Zion College of Engineering and Technology, Pudukkottai, Tamil Nadu, India for providing the facilities for this research work.
Author information
Authors and Affiliations
Contributions
M. Saravana Kumar: Conceptualization, Methodology, Investigation, E.Mohan - review & editing, Project administration, S.Robinson - review & editing, Supervision, D.ThivyaPrasad– review & editing.
Corresponding author
Ethics declarations
Conflict of Interest
The authors have no conflicts of interest to declare that are relevant to the content of this article.
Consent to Participate
This article does not contain any studies with human participants performed by any of the authors.
Consent to Publish
The authors provide their consent to publish this work in Silicon.
Ethical Approval
This article does not contain any studies with human participants or animals performed by any of the authors.
Additional information
Publisher’s Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Saravana Kumar, M., Mohan, E., Robinson, S. et al. Comparative Study on Morphological, Physical and Mechanical Characteristics of L-PBF Based AlSi10Mg Parts with Conventional Stir Casted Al-10 %SiC Composites. Silicon 14, 2695–2706 (2022). https://doi.org/10.1007/s12633-021-01065-9
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12633-021-01065-9