Mechanical properties of additively manufactured AlSi10Mg under quasi-static and cyclic loading

This study examines the effects of minor variations in the building angle of 3D-printed AlSi10Mg components on mechanical properties under different processing and postprocessing conditions (as-built [AB], stress relief [SR], and platform heating [HP]). Beginning with tensile tests to determine stress ranges for subsequent fatigue experiments, findings indicate that the building angle significantly impacts tensile strength, yield strength, and ultimate strain, rising with inclining angles. However, Young's modulus remains unaffected. High-cycle fatigue testing at stress amplitudes below yield strength values reveals differences in S-N fatigue curves among AB, SR, and HP conditions. While the building angle's influence is not statistically significant, AB samples exhibit lower fatigue resistance than SR and HP counterparts. HP samples perform similarly to SR at high stress levels but notably worse at low stress values. The developed multiple linear regression model shows reasonable accuracy, with 84% of predictions within +/- 2-factor and 97.2% within +/- 3-factor. Tensile strength and ultimate strain increase with inclining building angles. Eighty-four percent of the predictions of regression model fell within the +/- 2-factor error range. The fracture surface shows the crack initiation and propagation area, and the final fracture zone. The fatigue crack originated near the surface shows the presence of multiple initiation spots.