PSI - Issue 53

Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2022) 000–000

www.elsevier.com/locate/procedia

ScienceDirect

Procedia Structural Integrity 53 (2024) 12–28

© 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0 ) Peer-review under responsibility of the scientific committee of the ESIAM23 chairpersons Abstract High surface roughness observed in the as-built condition is still a limiting factor for metal parts processed by laser powder bed fusion (L-PBF). This is mainly due to the highly degrading effect of poor surface quality on fatigue performance. As a promising in-process alternative, the dual-laser powder bed fusion (dL-PBF) technique has recently been proven to increase the surface quality and fatigue life of L-PBF metal parts with up-facing inclined surfaces, reducing the need for additional post-treatments. This paper shows the beneficial effect of dL-PBF on the three-point bending fatigue life of lightweight high-strength hybrid particle reinforced (Ti+B 4 C)/Al-Cu-Mg metal matrix composite coupons, while comparing the dL-PBF processed to the as-built (AB), electric-discharge machined (EDM) and conventionally machined (milled) conditions. The effect of different surface conditions on several fatigue-influencing factors, i.e., surface roughness and concomitant roughness-induced stress concentration factor, surface residual stress, and hardness is discussed, as well as the resultant fatigue performance. The 73 % surface roughness reduction is identified as the major dL-PBF-influenced factor, leading to significantly enhanced fatigue life values that approach those of conventionally machined surfaces. © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license ( https://creativecommons.org/licenses/by-nc-nd/4.0 ) Peer-review under responsibility of the scientific committee of the ESIAM23 chairpersons Third European Conference on the Structural Integrity of Additively Manufactured Materials (ESIAM23) Improved surface quality and fatigue life of high-strength, hybrid particle reinforced (Ti+B 4 C)/Al-Cu-Mg metal matrix composite processed by dual-laser powder bed fusion S. Senol a *, A. Cutolo b , D. Ordnung b , A. Datye c , B. Van Hooreweder b , K. Vanmeensel a a KU Leuven, Dept. Materials Engineering (MTM), Research unit SeMPeR, Kasteelpark Arenberg 44, 3001 Leuven, Belgium b KU Leuven, Dept. of Mechanical Engineering, Research unit MaPS, Celestijnenlaan 300, 3001 Leuven, Belgium c Department of Mechanical Engineering and Materials Science, Yale University, New Haven, USA

* Corresponding author: E-mail address: seren.senol@kuleuven.be

2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license ( https://creativecommons.org/licenses/by-nc-nd/4. 0 ) Peer-review under responsibility of the scientific committee of the ESIAM23 chairpersons

2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the ESIAM23 chairpersons 10.1016/j.prostr.2024.01.003