Additively manufactured Al-Ce-Ni-Mn alloy with improved elevated-temperature fatigue resistance

Richard A. Michi; Joseph J. Simpson; Sumit Bahl; Quinn Campbell; Paul Brackman; Alex Plotkowski; Ryan R. Dehoff; J. A. Haynes; Qigui Wang; Amit Shyam

doi:10.1016/j.addma.2023.103477

Additively manufactured Al-Ce-Ni-Mn alloy with improved elevated-temperature fatigue resistance

Richard A. Michi, Joseph J. Simpson, Sumit Bahl, Quinn Campbell, Paul Brackman, Alex Plotkowski, Ryan R. Dehoff, J. A. Haynes, Qigui Wang, Amit Shyam

Research output: Contribution to journal › Article › peer-review

9 Scopus citations

Abstract

The high cycle fatigue behavior of an additively manufactured (AM) Al-10.5Ce-3.1Ni-1.2Mn wt% alloy was evaluated at 350 °C. The measured fatigue strength of 50 MPa at this temperature is comparable to the most fatigue resistant wrought Al alloys (2618-T6 and 7079-T6) at 315 °C. Refinement of pore populations through advanced AM processing in the examined alloy led to oxide inclusions becoming dominant fatigue crack initiation sites. The distribution of microstructural features that determine crack initiation was measured by X-ray computed tomography and served as input to make fatigue strength model predictions with various methodologies. A Monte-Carlo based approach that was previously applied to predict the fatigue strength of cast aluminum alloys through pore size distributions yielded accurate predictions for the fatigue strength of this AM alloy. Given the tunability of defect distributions in AM alloys, the sensitivity of the Al-Ce-Ni-Mn alloy fatigue behavior to defect distributions and outstanding elevated-temperature fatigue resistance of this alloy; the results together suggest the possibility of a new generation of fatigue-resistant alloys produced by the additive manufacturing route.

Original language	English
Article number	103477
Journal	Additive Manufacturing
Volume	66
DOIs	https://doi.org/10.1016/j.addma.2023.103477
State	Published - Mar 25 2023

Funding

Notice: This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( https://www.energy.gov/downloads/doe-public-access-plan ). Research was co-sponsored the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office (RM, JS, QC, AP, RD) and Vehicle Technologies Office's Powertrain Materials Core Program (RM, JS, SB, AP, JH, AS). We would like to thank Dana McClurg, Shane Hawkins, and Andres Marquez Rossy for their technical assistance.

Funders	Funder number
U.S. Department of Energy
Advanced Manufacturing Office
Office of Energy Efficiency and Renewable Energy

Keywords

Additive manufacturing
Al-Ce-Ni-Mn alloy
Elevated-temperature fatigue
X-ray computed tomography

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1016/j.addma.2023.103477

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title = "Additively manufactured Al-Ce-Ni-Mn alloy with improved elevated-temperature fatigue resistance",

abstract = "The high cycle fatigue behavior of an additively manufactured (AM) Al-10.5Ce-3.1Ni-1.2Mn wt% alloy was evaluated at 350 °C. The measured fatigue strength of 50 MPa at this temperature is comparable to the most fatigue resistant wrought Al alloys (2618-T6 and 7079-T6) at 315 °C. Refinement of pore populations through advanced AM processing in the examined alloy led to oxide inclusions becoming dominant fatigue crack initiation sites. The distribution of microstructural features that determine crack initiation was measured by X-ray computed tomography and served as input to make fatigue strength model predictions with various methodologies. A Monte-Carlo based approach that was previously applied to predict the fatigue strength of cast aluminum alloys through pore size distributions yielded accurate predictions for the fatigue strength of this AM alloy. Given the tunability of defect distributions in AM alloys, the sensitivity of the Al-Ce-Ni-Mn alloy fatigue behavior to defect distributions and outstanding elevated-temperature fatigue resistance of this alloy; the results together suggest the possibility of a new generation of fatigue-resistant alloys produced by the additive manufacturing route.",

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author = "Michi, {Richard A.} and Simpson, {Joseph J.} and Sumit Bahl and Quinn Campbell and Paul Brackman and Alex Plotkowski and Dehoff, {Ryan R.} and Haynes, {J. A.} and Qigui Wang and Amit Shyam",

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AU - Michi, Richard A.

AU - Simpson, Joseph J.

AU - Bahl, Sumit

AU - Campbell, Quinn

AU - Brackman, Paul

AU - Plotkowski, Alex

AU - Dehoff, Ryan R.

AU - Haynes, J. A.

AU - Wang, Qigui

AU - Shyam, Amit

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N2 - The high cycle fatigue behavior of an additively manufactured (AM) Al-10.5Ce-3.1Ni-1.2Mn wt% alloy was evaluated at 350 °C. The measured fatigue strength of 50 MPa at this temperature is comparable to the most fatigue resistant wrought Al alloys (2618-T6 and 7079-T6) at 315 °C. Refinement of pore populations through advanced AM processing in the examined alloy led to oxide inclusions becoming dominant fatigue crack initiation sites. The distribution of microstructural features that determine crack initiation was measured by X-ray computed tomography and served as input to make fatigue strength model predictions with various methodologies. A Monte-Carlo based approach that was previously applied to predict the fatigue strength of cast aluminum alloys through pore size distributions yielded accurate predictions for the fatigue strength of this AM alloy. Given the tunability of defect distributions in AM alloys, the sensitivity of the Al-Ce-Ni-Mn alloy fatigue behavior to defect distributions and outstanding elevated-temperature fatigue resistance of this alloy; the results together suggest the possibility of a new generation of fatigue-resistant alloys produced by the additive manufacturing route.

AB - The high cycle fatigue behavior of an additively manufactured (AM) Al-10.5Ce-3.1Ni-1.2Mn wt% alloy was evaluated at 350 °C. The measured fatigue strength of 50 MPa at this temperature is comparable to the most fatigue resistant wrought Al alloys (2618-T6 and 7079-T6) at 315 °C. Refinement of pore populations through advanced AM processing in the examined alloy led to oxide inclusions becoming dominant fatigue crack initiation sites. The distribution of microstructural features that determine crack initiation was measured by X-ray computed tomography and served as input to make fatigue strength model predictions with various methodologies. A Monte-Carlo based approach that was previously applied to predict the fatigue strength of cast aluminum alloys through pore size distributions yielded accurate predictions for the fatigue strength of this AM alloy. Given the tunability of defect distributions in AM alloys, the sensitivity of the Al-Ce-Ni-Mn alloy fatigue behavior to defect distributions and outstanding elevated-temperature fatigue resistance of this alloy; the results together suggest the possibility of a new generation of fatigue-resistant alloys produced by the additive manufacturing route.

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KW - X-ray computed tomography

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Additively manufactured Al-Ce-Ni-Mn alloy with improved elevated-temperature fatigue resistance

Abstract

Funding

Keywords

UN SDGs

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