Technische Hochschule Ingolstadt
AlSi10Mg is one of the widely used standard aluminum alloys in additive manufacturing, being the material of choice when it comes to applications like prototype manufacturing in the automotive industry. Unfortunately, the mechanical properties remain mostly behind those of the cast parts, drastically limiting the use. Various approaches to address this issue have been proposed. Most of them come with increased costs, making them economically unfeasible for high-volume applications. In this work, the chosen way to improve mechanical properties of the aluminium standard alloy, while maintaining its positive characteristics, is the addition of Zirconium. The focus was to enhance fatigue resistance properties by modifying the alloy system with varying amounts of Zirconium, without the need for additional heat treatments or extensive optimization of printing parameters. In addition to the examination of the new and the standard alloys, comprehensive mechanical testing was conducted. It has been demonstrated that adding Zirconium enables the creation of a more isotropic microstructure, while requiring only minor adjustment of standard printing parameters. Although in cyclic fatigue tests at room temperature, alloys with Zirconium exhibit significantly higher cycle numbers, the beneficial effect cannot be indefinitely enhanced by increasing the Zirconium content. Over a certain weight percentage, the impact on mechanical properties is negative.
Abstract
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