PSI - Issue 34

Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2019) 000–000

www.elsevier.com/locate/procedia

ScienceDirect

Procedia Structural Integrity 34 (2021) 184–190

© 2021 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 Esiam organisers Abstract Laser Powder Bed Fusion is considered as one of the most innovative manufacturing technologies and has rapidly gained interest in industry because it allows to produce near-net-shape metal components characterized by complex geometry. The structural integrity of parts with geometrical characteristics driven by optimized lightweight trade-offs should be verified before they are considered for critical applications in sectors such as automotive and aerospace. In this work a case study is presented: topology optimization is performed on a down-scaled automotive component with target definition of in terms of weight to stiffness ratio. An integrated design workflow of a metal AM part (i.e., from geometrical topological optimization to AM process simulation before production), ii) the actual part fabrication in an industrial-grade L-PBF system using the AlSi10Mg alloy powder and iii) structural qualification by fatigue testing of actual parts. The material selected for the study is AlSi10Mg, an alloy typically used in the automotive field. An SLM500 system with process parameters of 50 µ m as layer thickness is used to produce components to be fatigue tested in the laboratory. Knowledge of the link between technology-dependent factors and the fatigue strength was determined with a specific test methodology using miniature specimens. The anisotropic fatigue behavior obtained with specimens revealed the key role of residual stresses for as-built L-PBF AlSi10Mg. Prediction of the fatigue response of the optimized L-PBF part benefited from extensive modeling and simulation activities and ad-hoc material testing. © 2020 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) The second European Conference on the Structural Integrity of Additively Manufactured Materials Design, production, and fatigue testing of an optimized structural component made of L-PBF AlSi10Mg Federico Uriati a , Luca Zambrelli a , Gianni Nicoletto a, Michele Garibaldi b, a University of Parma, Dept. of Engineering and Architecture, 43124 Parma, Italy b Beam-IT Spa, Strada Pinzera, 17, 43045 Fornovo di Taro PR, Italy

Peer-review under responsibility of the scientific committee of the ESIAM organisers Keywords: structural optimization fatigue; part integrity; powder bed fusion; AlSi10Mg Corresponding author : federico.uriati@unipr.it

1. Introduction Metal additive manufacturing and specifically Laser Powder Bed Fusion,(Frazier 2014), is considered as one of the most innovative manufacturing technology and has rapidly gained interest in industry because it allows to produce

2452-3216 © 2020 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 Esiam organisers

2452-3216 © 2021 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 Esiam organisers 10.1016/j.prostr.2021.12.027