Fatigue performance of TPMS-based AlSi10Mg architected cellular materials fabricated via hybrid and powder bed fusion methods

Agyapal Singh, Abdulrahman Jaber, Nikolaos Karathanasopoulos

Research output: Contribution to journalArticlepeer-review

Abstract

This work investigates the fatigue performance of AlSi10Mg-based architected materials fabricated using hybrid manufacturing and powder bed fusion (PBF) methods. For the analysis, cellular materials with triply periodic minimal surface (TPMS) topologies, including Gyroid and IWP architectures are manufactured and subject to load-controlled, compression-compression, cyclic loading. Quantitative fatigue performance comparisons of hybrid manufactured (cast) with PBF as-built (PBF-AB) and heat-treated (PBF-HT) samples are performed. Cast samples exhibit the highest fatigue rigidity, and resistance to permanent deformation and fatigue damage, followed by PBF-HT samples, with PBF-AB samples yielding the shortest fatigue life. Gyroid 30 % samples consistently outperform Gyroid 20 % and IWP 30 % designs. The dependence of the fatigue performance of PBF-HT samples on the loading frequency and directionality are investigated, with lower loading frequencies and out-of-building plane loads resulting in a significant accumulation of fatigue ratcheting and fatigue damage strains, respectively. The post-fatigue analysis of the quasi-static stress–strain behavior confirms that cast samples maintain high structural integrity, and a low degradation of mechanical properties over a large number of loading cycles. The analysis provides benchmark results on the process-structure-property relationship of advanced AlSi10Mg materials as a function of their manufacturing method and cyclic loading performance.

Original languageEnglish (US)
Article number108758
JournalInternational Journal of Fatigue
Volume193
DOIs
StatePublished - Apr 2025

Keywords

  • Additive manufacturing
  • Fatigue
  • Finite elements
  • Investment casting
  • Metamaterials
  • PBF

ASJC Scopus subject areas

  • Modeling and Simulation
  • General Materials Science
  • Mechanics of Materials
  • Mechanical Engineering
  • Industrial and Manufacturing Engineering

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