Mattia Zanni

The AlSi10Mg alloy produced by laser-based powder bed fusion (L-PBF) is widely used to produce high-value-added structural parts subjected to cyclic mechanical loads at high temperatures. The paper aims to widen the knowledge of the room- and high-temperature (200 °C) fatigue behavior of the L-PBF AlSi10Mg alloy by analyzing the fully reversed rotating bending test results on mechanically polished specimens. Two heat-treated conditions are analyzed: T5 (direct artificial aging: 4 h at 160 °C) and novel T6R (rapid solution: 10 min at 510 °C, artificial aging: 6 h at 160 °C). The study highlights that (i) the T6R alloy is characterized by higher fatigue strength at room (108 MPa) and high temperatures (92 MPa) than the T5 alloy (92 and 78 MPa, respectively); (ii) thermal exposure at 200 °C up to 17 h does not introduce macroscopical microstructural variation; (iii) fracture surfaces of the room- and high-temperature-tested specimens show comparable crack initiation, mostly from sub-superficial gas and keyhole pores, and failure propagation mechanisms. In conclusion, the L-PBF AlSi10Mg alloy offers good cyclic mechanical performances under various operating conditions, especially for the T6R alloy, and could be considered for structural components operating at temperatures up to 200 °C.