L-DED and L-PBF Additive Manufactured AlSi10Mg Alloy: Mechanical Characterization and Very-High Cycle Fatigue Performance

Aluminum (Al) parts for the electrical industry are subjected to cyclic loads, making their fatigue life critical. Owing to its properties, AlSi10Mg alloy is largely employed in this field. Additive manufacturing (AM) is rising as a new technology to fulfill the demand for spare parts. Laser Directed Energy Deposition (L-DED) and Laser Powder Bed Fusion (L-PBF) can manufacture customized components with larger dimensions and greater geometric resolution, respectively. However, there are challenges in processing AlSi10Mg by AM, like controlling oxygen and moisture atmosphere contents, which negatively affect the processability and component properties. To ensure multilayer parts with appropriate microstructure and mechanical properties, L-DED and L-PBF processing parameters must be properly investigated. In this context, processing parameters and build strategies for an AlSi10Mg alloy were developed for L-DED and L-PBF. The performance of AM-manufactured AlSi10Mg was benchmarked to reference casting. Archimedes’ density, optical microscopy porosity, computed tomography, optical and scanning electron microscopy, hardness, tensile, Charpy impact, and VHCF tests were performed. The results suggest comparable VHCF performance, despite the slight differences observed in mechanical properties, porosity, and microstructure characteristics between L-PBF and L-DED specimens.