Vol. 26 No. 3 2024 3 EDITORIAL COUNCIL EDITORIAL BOARD EDITOR-IN-CHIEF: Anatoliy A. Bataev, D.Sc. (Engineering), Professor, Rector, Novosibirsk State Technical University, Novosibirsk, Russian Federation DEPUTIES EDITOR-IN-CHIEF: Vladimir V. Ivancivsky, D.Sc. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Vadim Y. Skeeba, Ph.D. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Editor of the English translation: Elena A. Lozhkina, Ph.D. (Engineering), Department of Material Science in Mechanical Engineering, Novosibirsk State Technical University, Novosibirsk, Russian Federation The journal is issued since 1999 Publication frequency – 4 numbers a year Data on the journal are published in «Ulrich's Periodical Directory» Journal “Obrabotka Metallov” (“Metal Working and Material Science”) has been Indexed in Clarivate Analytics Services. Novosibirsk State Technical University, Prospekt K. Marksa, 20, Novosibirsk, 630073, Russia Tel.: +7 (383) 346-17-75 http://journals.nstu.ru/obrabotka_metallov E-mail: metal_working@mail.ru; metal_working@corp.nstu.ru Journal “Obrabotka Metallov – Metal Working and Material Science” is indexed in the world's largest abstracting bibliographic and scientometric databases Web of Science and Scopus. Journal “Obrabotka Metallov” (“Metal Working & Material Science”) has entered into an electronic licensing relationship with EBSCO Publishing, the world's leading aggregator of full text journals, magazines and eBooks. The full text of JOURNAL can be found in the EBSCOhost™ databases.
OBRABOTKAMETALLOV Vol. 26 No. 3 2024 4 EDITORIAL COUNCIL EDITORIAL COUNCIL CHAIRMAN: Nikolai V. Pustovoy, D.Sc. (Engineering), Professor, President, Novosibirsk State Technical University, Novosibirsk, Russian Federation MEMBERS: The Federative Republic of Brazil: Alberto Moreira Jorge Junior, Dr.-Ing., Full Professor; Federal University of São Carlos, São Carlos The Federal Republic of Germany: Moniko Greif, Dr.-Ing., Professor, Hochschule RheinMain University of Applied Sciences, Russelsheim Florian Nürnberger, Dr.-Ing., Chief Engineer and Head of the Department “Technology of Materials”, Leibniz Universität Hannover, Garbsen; Thomas Hassel, Dr.-Ing., Head of Underwater Technology Center Hanover, Leibniz Universität Hannover, Garbsen The Spain: Andrey L. Chuvilin, Ph.D. (Physics and Mathematics), Ikerbasque Research Professor, Head of Electron Microscopy Laboratory “CIC nanoGUNE”, San Sebastian The Republic of Belarus: Fyodor I. Panteleenko, D.Sc. (Engineering), Professor, First Vice-Rector, Corresponding Member of National Academy of Sciences of Belarus, Belarusian National Technical University, Minsk The Ukraine: Sergiy V. Kovalevskyy, D.Sc. (Engineering), Professor, Vice Rector for Research and Academic Aff airs, Donbass State Engineering Academy, Kramatorsk The Russian Federation: Vladimir G. Atapin, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Victor P. Balkov, Deputy general director, Research and Development Tooling Institute “VNIIINSTRUMENT”, Moscow; Vladimir A. Bataev, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Vladimir G. Burov, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Aleksandr N. Korotkov, D.Sc. (Engineering), Professor, Kuzbass State Technical University, Kemerovo; Dmitry V. Lobanov, D.Sc. (Engineering), Associate Professor, I.N. Ulianov Chuvash State University, Cheboksary; Aleksey V. Makarov, D.Sc. (Engineering), Corresponding Member of RAS, Head of division, Head of laboratory (Laboratory of Mechanical Properties) M.N. Miheev Institute of Metal Physics, Russian Academy of Sciences (Ural Branch), Yekaterinburg; Aleksandr G. Ovcharenko, D.Sc. (Engineering), Professor, Biysk Technological Institute, Biysk; Yuriy N. Saraev, D.Sc. (Engineering), Professor, V.P. Larionov Institute of the Physical-Technical Problems of the North of the Siberian Branch of the RAS, Yakutsk; Alexander S. Yanyushkin, D.Sc. (Engineering), Professor, I.N. Ulianov Chuvash State University, Cheboksary
Vol. 26 No. 3 2024 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Sukhov A.V., Sundukov S.K., Fatyukhin D.S. Assembly of threaded and adhesive-threaded joints with the application of ultrasonic vibrations...................................................................................................................................... 6 Baraboshkin K.A., Adigamov R.R., Yusupov V.S., Kozhevnikova I.A., Karlina A.I. Thermomechanical rolling in well casing production (research review)......................................................................................................................... 24 Dwivedi R., Somatkar A., Chinchanikar S. Modeling and optimization of roller burnishing of Al6061-T6 process for minimum surface roughness, better microhardness and roundness................................................................................ 52 Ilinykh A.S., Pikalov A.S., Miloradovich V.K., Galay M.S. Experimental studies of rail grinding modes using a new high-speed electric drive...................................................................................................................................................... 66 Karlina Yu.I., Konyukhov V.Yu., Oparina T.A. Assessment of the possibility of resistance butt welding of pipes made of heat-resistant steel 0.15C-5Cr-Mo................................................................................................................................... 79 Gimadeev M.R., Stelmakov V.A., Shelenok E.A. Product life cycle: machining processes monitoring and vibroacoustic signals fi lterings.................................................................................................................................................................... 94 EQUIPMENT. INSTRUMENTS Zakovorotny V.L., Gvindjiliya V.E., Kislov K.V. Information properties of frequency characteristics of dynamic cutting systems in the diagnosis of tool wear....................................................................................................................... 114 Ablyaz T.R., Blokhin V.B., Shlykov E.S., Muratov K.R., Osinnikov I.V. Features of the use of tool electrodes manufactured by additive technologies in electrical discharge machining of products....................................................... 135 Sidorov E.A., GrinenkoA.V., ChumaevskyA.V., Panfi lovA.O., Knyazhev E.O., NikolaevaA.V., CheremnovA.M., Rubtsov V.E., Utyaganova V.R., Osipovich K.S., Kolubaev E.A. Patterns of reverse-polarity plasma torches wear during cutting of thick rolled sheets..................................................................................................................................... 149 MATERIAL SCIENCE Semin V.O., Panfi lov A.O., Utyaganova V.R., Vorontsov A.V., Zykova A.P. Corrosion properties of CuAl9Mn2/ER 321 composites formed by dual-wire-feed electron beam additive manufacturing................................ 163 Dewangan R., Sharma B.P., Sharma S.S. Investigation of hardness behavior in aluminum matrix composites reinforced with coconut shell ash and red mud using Taguchi analysis............................................................................ 179 Saprykina N.А., Saprykin A.А., Sharkeev Y.P., Ibragimov E.А. The eff ect of technological parameters on the microstructure and properties of the AlSiMg alloy obtained by selective laser melting......................................................... 192 Burdilov A.A., Dovzhenko G.D., Bataev I.A., Bataev A.A. Methods of synchrotron radiation monochromatization (research review).................................................................................................................................................................. 208 Burkov A.A., Dvornik M.A., Kulik M.A., Bytsura A.Yu. Wear resistance and corrosion behavior of Cu-Ti coatings in SBF solution..................................................................................................................................................................... 234 Pugacheva N.B., Bykova T.M., Sirosh V.A., MakarovA.V. Structural features and tribological properties of multilayer high-temperature plasma coatings........................................................................................................................................ 250 Sharma B.P., Dewangan R., Sharma S.S. Characterizing the mechanical behavior of eco-friendly hybrid polymer composites with jute and Sida cordifolia fi bers.................................................................................................................... 267 Kornienko E.E., Gulyaev I.P., Smirnov A.I., Plotnikova N.V., Kuzmin V.I., Golovakhin V., Tambovtsev A.S., Tyryshkin P.A., Sergachev D.V. Fine structure features of Ni-Al coatings obtained by high velocity atmospheric plasma spraying.................................................................................................................................................................... 286 EDITORIALMATERIALS 298 FOUNDERS MATERIALS 307 CONTENTS
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 3 2024 The effect of technological parameters on the microstructure and properties of the AlSiMg alloy obtained by selective laser melting Natalia Saprykina 1, a, *, Alexandr Saprykin 1, b, Yurii Sharkeev 2, c, Egor Ibragimov 1, d 1 National Research Tomsk Polytechnic University, 30 Lenin Avenue, Tomsk, 634050, Russian Federation 2 Institute of Strength Physics and Materials Sciences SB RAS, 2/4, pr. Akademicheskii, Tomsk, 634055, Russian Federation a https://orcid.org/0000-0002-6391-6345, saprikina@tpu.ru; b https://orcid.org/0000-0002-6518-1792, sapraa@tpu.ru; c https://orcid.org/0000-0001-5037-245X, sharkeev@ispms.tsc.ru; d https://orcid.org/0000-0002-5499-3891, egor83rus@tpu.ru Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2024 vol. 26 no. 3 pp. 192–207 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2024-26.3-192-207 ART I CLE I NFO Article history: Received: 05 June 2024 Revised: 17 June 2024 Accepted: 28 June 2024 Available online: 15 September 2024 Keywords: Selective laser melting Metal Powder Porosity Scanning strategy Modes of selective laser melting Microhardness Energy deposition Aluminum-silicon-magnesium alloy system Funding The research was carried out at the expense of a grant from the Russian Science Foundation No. 22-29-01491, https://rscf.ru/project/22-29-01491/ Acknowledgements Authors would like to thank to Ph.D. M.A. Khimich, Ph.D. V.V. Chebodaeva, I.A. Glukhov for their help in conducting research. The equipment of the NMNT TPU Central Control Center was used in the work. ABSTRACT Introduction. The development of additive technologies is aimed at the synthesis of new powder compositions for selective laser melting plants, the study of the effect of mode parameters on the stable quality of products. The purpose of this work is to study the effect of the scanning strategy on the microstructure, elemental composition, porosity and density of specimens obtained by selective laser melting from non-spherical powders (Al — 91 wt. %, Si — 8 wt. %, Mg — 1 wt. %), subjected to special preparation to determine the optimal conditions for selective laser melting. The research methods are methods of X-ray diffraction and X-ray phase analysis, transmission electron microscopy. The paper examines specimens formed using four different scanning strategies. Results and discussions. A promising aluminum alloy AlSi8Mg is developed for selective laser melting. The material has good manufacturability and low powder cost. The technological parameters of melting make it possible to form a thin structure with a low level of porosity. The mechanism of influence of the scanning strategy on porosity, surface morphology, relative density and microstructure is investigated. A specimen from the AlSi8Mg powder composition with a high relative density of 99.97 % is produced by selective laser melting with an energy density of 200 J/mm3, a specimen scanning circuit when the direction of laser movement changes by an angle of 90° each odd layer. It is proved that the density of the AlSiMg alloy depends on the scanning strategy used. The calculated density of the specimen was 2.5 g/cm3, which corresponds to the density of silumin. Analysis of SEM images and maps of the distribution of elements (Al, Mg, Si) of the specimens showed that different specimen formation strategies do not affect the nature of silicon distribution. A unique grain structure is observed in the resulting AlSi8Mg alloy. The melt pool consists of small grains along the border and large grains in the center. The formation of fine grains is explained by the addition of Si and the high cooling rate during selective laser melting. For citation: Saprykina N.А., Saprykin A.А., Sharkeev Y.P., Ibragimov E.А. The effect of technological parameters on the microstructure and properties of the AlSiMg alloy obtained by selective laser melting. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2024, vol. 26, no. 3, pp. 192–207. DOI: 10.17212/1994-6309-2024-26.3-192-207. (In Russian). ______ * Corresponding author Saprykina Natalia A., Ph.D. (Engineering), Associate Professor National Research Tomsk Polytechnic University, 30 Lenin Ave., 634050, Tomsk, Russian Federation Tel.: +7 923 49-72-483, e-mail: saprikina@tpu.ru
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 3 2024 Introduction Selective laser melting (SLM) is an additive manufacturing (AM) technology in which metal powder is melted by a laser beam along a given trajectory to make products layer by layer. Compared with traditional manufacturing technologies, SLM has a number of advantages, such as rapid prototyping, production of complex-shaped parts and reduced lead time. The technology is developing towards synthesizing new powder compositions for SLM units, studying the influence of mode parameters upon the stable quality of the products, repeatability and reproducibility of the process on different devices [1]. Aluminum and aluminum-based powders are some of the most common materials in the automotive, aerospace and aviation industries due to its excellent strength-to-weight ratio, good thermal and electrical conductivity, and corrosion resistance. Recently, aluminum-based powder has also been the object of research for use in selective laser melting units [2]. This technology allows not only to shorten the design and production cycle, but also to obtain an alloy with a unique structure as metal powder is rapidly melted and cooled [3]. Currently, there are many studies concerning production of various items from aluminum-based powders using the SLM technology [4–6], and recommendations are given to improve the quality of the resulting products. Thus, when determining the SLM conditions, the following physical properties of aluminum are taken into account: high thermal expansion coefficient, high shrinkage during solidification, low level of laser energy absorption, formation of strong oxide layer, high thermal conductivity, relatively wide range of solidification temperatures [7–9]. Defects of the surface and internal structure, such as porosity, layer distortion, cracking, low dimensional accuracy and surface roughness occurred in the process of selective laser melting of aluminum-based powders [10]. These defects are often associated with development of uneven temperature gradients along the fused surface, with contamination of powder by oxides, with inhomogeneity of surface tension which prevents the adhesion of the melt to the substrate and interlayer bonding [11]. All the studies were completed on the specimens produced from the special spherical powders of the necessary alloys which cost a lot. The relative density of the specimens made from spherical powders is over 99.5 %. It was obtained by optimizing laser scanning parameters from AlSi10Mg [12], [13], Al12Si [14] and AlSi7Mg [15] alloys. In addition, these specimens showed excellent mechanical properties of the formed fine cellular dendrite microstructure, which results from the SLM process [16]. Despite the advances in the field of additive technologies, only a limited number of aluminum alloys can be used to produce a high-quality product using the SLM method [17]. Completely dense and crack-free specimens from aluminum-based powders can be produced using SLM in a narrow range of modes [18, 19], which is selected experimentally for each material. The research for non-spherical powders has not been described by scientists. The SLM conditions include over 120 parameters that, to one degree or another, affect the quality of the resulting product. Beside the selective laser melting mode the scanning strategy is also one of the processing parameters that affects the microstructure formation and the properties of the resulting products. By controlling the direction of the heat flow between the layers through the laser beam scanning strategy it is possible to form various grain structures and change the direction of the interlayer grains growth [20]. High energy consumption and uneven temperature distribution lead to huge temperature gradients, high thermal stresses and deformation. Thermal temperature gradients, direction of the heat flow and the cooling rate have a very important influence upon the dislocation density, grain size and texture of the manufactured products. The purpose of the given paper is to study the influence of the scanning strategy on the microstructure, elemental composition, porosity and density of the specimens produced by selective laser melting from non-spherical powders (Al – 91 wt. %, Si – 8 wt. %, Mg – 1 wt. %) specially prepared as described in the previously published papers [21] to determine optimal SLM conditions. This purpose requires solving the following problems: producing specimens from the prepared powder composition [21] using the selective laser melting method with different scanning strategies; identifying of the optimal scanning strategy, which allows producing a specimen with the lowest porosity without changing other melting parameters; determining the density of the specimens, studying the structural and phase composition of the specimen using the transmission microscopy method.
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 3 2024 Research methods The research was carried out on a 3D printer VARISKAF-100MVS manufactured in Yurga Institute of Technology of Tomsk Polytechnic University. The unit is equipped with a 100 W ytterbium fiber laser with a wavelength of 1,070 nm. The process of formation and study of the AlSiMg powder from single-component powders of aluminum, silicon and magnesium was described previously in [21]. To analyze the influence of the scanning strategy on the microstructure, elemental composition, porosity and density of the specimens the conditions were determined by search experiments and described in the paper [22]. Specimens with a size of 10×10×3 mm were produced under the following mode parameters: scanning speed V = 225 mm/s, scanning step S = 0.08 mm, laser power P = 90 W, powder layer thickness h = 0.025 mm. The temperature of the working table at the beginning of the SLM cycle was +25 °C; the powder was melted in the protective argon environment. An energy density of 200 J/mm3 provided sufficient heat to melt the powder and promoted the remelting of the part of the previous layer and melt path to smoothly connect the adjacent layers [22]. After formation the specimens were ground and polished using diamond pastes, removing 400 µm of the top layer. Porosity was determined as the average value from nine optical images of the polished section surface. The shooting pattern is shown in Figure 1. Fig. 1. Shooting pattern Studies of the structural-phase state of the specimen were completed using a transmission electron microscope JEOL JEM-2100. Shooting conditions were as follows: accelerating voltage of 200 kV, magnification of 6,000– 1,500,000 times, “column length” under the microdiffraction mode of 100 cm. The phase identification was carried out using the international card database ICDDPDF4+ (International Center for Diffraction Data). To study the effect of scanning strategy on the microstructure and porosity of the specimens, four strategies were implemented. Scanning strategy I (∠ 90), in which the direction of laser movement changes by an angle of 90° from layer to layer, is shown in Figure 2. (See the marks below) Fig. 2. Scanning strategy I (∠ 90) With scanning strategy II (∠ 45) the direction of laser movement changes by an angle of 45° from layer to layer, see Figure 3.
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 3 2024 Fig. 3. Scanning strategy II (∠ 45) With scanning strategy III (∠ 90S/2), the specimen is formed when the direction of the laser movement changes by 90° every odd layer (n, n + 2, etc.). In every even layer (n + 1, n + 3), the direction of the laser beam is parallel to the previous layer, and the track is shifted by a distance of S/2. The strategy is shown in Figure 4. Fig. 4. Scanning strategy III (∠ 90S/2) Scanning strategy IV (∠ 90p.p.), in which each layer is scanned by the laser beam twice (double remelting) and during the second pass the step is shifted by S/2 while the direction of the laser movement changes by 90° from layer to layer. This scheme is shown in Figure 5. Fig. 5. Scanning strategy ⅠV (∠ 90 p.p.) Results and discussion The photographs of the structure of the specimens formed with the use of different scanning strategies from the composition of powders under the following SLM modes [22]: P = 90 W; v = 225 mm/s; S = 0.08 mm; h = 0.025 mm; t = 25 С°, are presented in Table 1.
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 3 2024 Ta b l e 1 Photos of the specimen structure and porosity values, % Scanning strategy I (∠ 90) 0.01 0.02 0.01 0.43 0.39 0.06 0.63 0.35 0.93 “Average” porosity is 0.31 % Scanning strategy II (∠ 45) 0.11 0.09 0.05
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 3 2024 0.18 0.14 0.06 0.11 1.36 0.47 “Average” porosity is 0.29 % Scanning strategy III (∠ 90S/2) 0.04 0.01 0.02 0.06 0.01 0.02 0.05 0.04 0.03 “Average” porosity is 0.03 % С o n t i n u a t i o n o f t h e t a b l e 1
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 3 2024 Scanning strategy ⅠV (∠ 90 p.p.) T h e E n d Ta b l e 1 As a result of double remelting large melt drops of 0.2–0.5 mm in size were formed on the surface of the layer which led to uneven application of the next powder layer and appearance of non-melts. For this reason it was not possible to build-up a specimen of the required thickness. For this specimen its porosity was not assessed due to impracticality. The graph of average porosity dependence upon the scanning strategy shows that the specimen obtained using strategy III has the lowest porosity value of 0.03 %, see Figure 6. Fig. 6. Dependence of the average porosity of the specimen on the scanning strategy Density is an important indicator for assessing the quality of the parts. A caliper was used to measure the overall dimensions of the specimens: length×width×height, which was 10×10×3 mm accordingly. Using an analytical balance VST-600/10 we measured the mass of the specimens, which amounted to 0.748 g for the specimen obtained using scanning strategy I, and 0.75 g for scanning strategy II. The calculated density of the specimens for scanning strategies I and II was 2.49 g/cm3, and for the specimen obtained using scanning strategy III, 2.5 g/cm3, which corresponds to the density of silumin. Figure 7 shows SEM images and element distribution maps (Al, Mg, Si) of the specimens obtained using different strategies. Aluminum and magnesium are distributed uniformly in all specimens. Silicon in the specimens is distributed in the form of small particles, less than 5 µm in size. Changing the specimen preparation strategy does not change the nature of silicon distribution in the specimens. The structural-phase state and elemental composition were determined for the specimen formed using scanning strategy III. The specimen under study has a grain structure; the microscopic pores are not detected at the magnifications used.
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 3 2024 a b Fig. 7. SEM images and distribution maps of elements (Al, Mg, Si) of specimens using different production strategies: а – No. 1; b – No. 2; c – No. 3 (see also next page)
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 3 2024 с Fig. 7. The End The microdiffraction patterns obtained from different areas are represented, first of all, by reflections of varying intensities. The identified reflections correspond to the BCC phase Al – 91 wt. %, Si – 8 wt. % (PDF Card – 04-003-7125). In the microdiffraction pattern, Figure 8 b, obtained using the largest field diaphragm at the low magnification of the specimen, there are also reflections located circumferentially which indicates that there are fine particles in the structure of the specimen. At high magnifications and dark-field images it is clearly visible that these fine particles are located at the grain boundaries. To analyze the homogeneity of element distribution in the specimen under study energy-dispersive microanalysis was used. First of all, element distribution maps throughout the analysis area were built. Mapping showed that the main element of the alloy, Al, is distributed evenly in the grains, but its content decreases along the grain boundaries. The second most abundant element, Si, on the contrary, is mainly concentrated along the grain boundaries. The third element in terms of content, Mg, is distributed evenly throughout the volume under study. Based on the nature of the total spectrum, Figure 9, no other elements are detected in the specimens. The elemental composition of the area under study is presented in Table 2. To confirm the local heterogeneity of the element composition we also completed the study of elemental composition along a given line. The results of the study are shown in Figure 10. The nature of elements distribution is similar to that of the mapping: at the grain boundaries we observe reduced Al and increased Si content. As can be seen the concentration of Mg, when studied using this method, is also heterogeneous. However, since the Mg content in the composition is low (less than 0.5 wt. % according the data of elemental analysis) this cannot be postulated accurately. A specimen of a complex geometric shape (Figure 11) was produced from the prepared powder mixture under the obtained optimal SLM conditions.
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 3 2024 Fig. 8. Microstructure of the AlSiMg alloy specimen: light-field images (а, d) with corresponding microdifraction patterns (b, e) and dark-field images (c, f) а b c d e f
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 3 2024 g Fig. 9. A bright field image of the analysis area (а), the desired TSM image of the analysis area (b), a TSM image for comparing element maps (c), element distribution maps (d–е) and the total spectrum of the mapping area (g) а b c d e f Ta b l e 2 Elemental analysis of the Al-Si-Mg alloy by the total spectrum from the mapping area Element Weight % Atomic % Al K 92.65 92.86 Si K 6.95 6.69 Mg K 0.40 0.45
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 3 2024 Fig. 11. A prototype of the swirler Fig. 10. A bright field image of the analysis area (а), the desired TSM image of the analysis area (b), a TSM image with plotted element content data (c), the distribution of elements along the track (d–f) а b c d e f
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 3 2024 Conclusion In the course of the research, a technology for forming a promising aluminum alloyAlSi8Mg for selective laser melting and non-spherical powders is developed. The material shows good manufacturability and low powder cost. The technological parameters of melting allow forming a fine structure with low porosity. The mechanism of the influence of the scanning strategy on porosity, surface morphology, relative density and microstructure is studied. The main conclusions are summarized as follows. A specimen was produced from AlSi8Mg powder composition with high relative density of 99.97 % by selective laser melting. The energy density significantly affects the quality of the surface. In this study the energy density of 200 J/mm3 and the specimen formation scanning strategy III when the direction of the laser movement changes by 90° every odd layer (n, n + 2, etc.) and in every even layer (n + 1, n + 3), the direction of the laser beam is parallel to the previous layer, and the track is shifted by a distance of S/2 (∠ 90S/2) are the best parameters of the process allowing to achieve the highest relative density. It is proven that the density of AlSiMg alloy depends on the scanning strategy used. The calculated density of the specimens for scanning strategies I and II was 2.49 g/cm3, and for the specimen obtained using scanning strategy III, 2.5 g/cm3, which corresponds to the density of silumin. Analysis of SEM images and element distribution maps (Al, Si, Mg) of the specimens showed that different strategies for producing specimens do not affect the nature of silicon distribution. Unique grain structure is observed in the finished AlSi8Mg alloy. In the melt pool small grains are located along the boundary, while large grains are in the center. Addition of silicon and high cooling rates are positive conditions for formation of fine grains. References 1. Oliveira J.P., LaLonde A.D., Ma J. Processing parameters in laser powder bed fusion metal additive manufacturing. Materials and Design, 2020, vol. 193 p. 108762. DOI: 10.1016/j.matdes.2020.108762. 2. Kanazawa M., Iwaki M., Minakuchi S., Naoyuki N. Fabrication of titanium alloy frameworks for complete dentures by selective laser melting. Journal of Prosthetic Dentistry, 2014, vol. 112 (6), pp. 1441–1447. – DOI: 10.1016/j. prosdent.2014.06.017. 3. Kotadia H.R., Gibbons G., Das A., Howes P.D. A review of laser powder bed fusion additive manufacturing of aluminium alloys: microstructure and properties. Additive Manufacturing, 2021, vol. 46, p. 102155. DOI: 10.1016/j. addma.2021.102155. 4. Wang Z.H., Lin X., Kang N., Wang Y.F., Yu X.B., Tan H., Yang H.O., Huang W.D. Making selective-lasermelted high-strength Al-Mg-Sc-Zr alloy tough via ultrafine and heterogeneous microstructure. Scripta Materialia, 2021, vol. 203, p. 114052. DOI: 10.1016/j.scriptamat.2021.114052. 5. Geng Y.X., Wang Y.M., Xu J.H., Mi S.B., Fan S.M., Xiao Y.K., Wu Y., Luan J.H. A high-strength AlSiMg1.4 alloy fabricated by selective laser melting. Journal of Alloys and Compounds, 2021, vol. 867, p. 159103. DOI: 10.1016/j.jallcom.2021.159103. 6. Zhang J.L., Gao J.B., Song B., Zhang L.J., Han C.J., Cai C., Zhou K., Shi Y.S.Anovel crack-free Ti-modifiedAlCu-Mg alloy designed for selective laser melting. Additive Manufacturing, 2021, vol. 38, p. 101829. DOI: 10.1016/j. addma.2020.101829. 7. Shah A.W., Ha S., Kim B., Yoon Y., Lim H., Kim S.K. Effect of Al2Ca addition and heat treatment on the microstructure modification and tensile properties of hypoeutectic Al–Mg–Si alloys. Materials, 2021, vol. 14, p. 4588. DOI: 10.3390/ma14164588. 8. Lefebvre W., Rose G., Delroisse P., Baustert E., Cuvilly F., Simar A. Nanoscale periodic gradients generated by laser powder bed fusion of an AlSi10Mg alloy. Materials and Design, 2021, vol. 197, p. 109264. DOI: 10.1016/j. matdes.2020.109264. 9. Bayoumy D., Schliephake D., Dietrich S., Wu X.H., Zhu Y.M., Huang A.J. Intensive processing optimization for achieving strong and ductile Al-Mn-Mg-Sc-Zr alloy produced by selective laser melting. Materials and Design, 2021, vol. 198, p. 109317. DOI: 10.1016/j.matdes.2020.109317. 10. Rao J.H., Zhang Y., Zhang K., Huang A., Davies C.H.J., Wu X. Multiple precipitation pathways in an Al7Si-0.6Mg alloy fabricated by selective laser melting, Scripta Materialia, 2019, vol. 160, pp. 66–69. DOI: 10.1016/j. scriptamat.2018.09.045.
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