Achieving ultrahigh fatigue resistance in AlSi10Mg alloy by additive manufacturing

Chengyi Dan; Yuchi Cui; Yi Wu; Zhe Chen; Hui Liu; Gang Ji; Yakai Xiao; Han Chen; Mingliang Wang; Jun Liu; Lei Wang; Yang Li; Ahmed Addad; Ying Zhou; Siming Ma; Qiwei Shi; Haowei Wang; Jian Lu

doi:10.1038/s41563-023-01651-9

Achieving ultrahigh fatigue resistance in AlSi10Mg alloy by additive manufacturing

Chengyi Dan (Co-first Author)
, Yuchi Cui (Co-first Author)
, Yi Wu (Co-first Author)
, Zhe Chen^* (Co-first Author)
, Hui Liu
, Gang Ji
, Yakai Xiao
, Han Chen
, Mingliang Wang
, Jun Liu
, Lei Wang
, Yang Li
, Ahmed Addad
, Ying Zhou
, Siming Ma
, Qiwei Shi
, Haowei Wang
, Jian Lu^*

^*Corresponding author for this work

Research output: Journal Publications and Reviews › RGC 21 - Publication in refereed journal › peer-review

172 Citations (Scopus)

Abstract

Since the first discovery of the fatigue phenomenon in the late 1830s, efforts to fight against fatigue failure have continued. Here we report a fatigue resistance phenomenon in nano-TiB₂-decorated AlSi10Mg enabled by additive manufacturing. This fatigue resistance mechanism benefits from the three-dimensional dual-phase cellular nanostructure, which acts as a strong volumetric nanocage to prevent localized damage accumulation, thus inhibiting fatigue crack initiation. The intrinsic fatigue strength limit of nano-TiB₂-decorated AlSi10Mg was proven to be close to its tensile strength through the in situ fatigue tests of a defect-free microsample. To demonstrate the practical applicability of this mechanism, printed bulk nano-TiB₂-decorated AlSi10Mg achieved fatigue resistance more than double those of other additive manufacturing Al alloys and surpassed those of high-strength wrought Al alloys. This strategy of additive-manufacturing-assisted nanostructure engineering can be extended to the development of other dual-phase fatigue-resistant metals. © 2023, The Author(s), under exclusive licence to Springer Nature Limited.

Original language	English
Pages (from-to)	1182–1188
Journal	Nature Materials
Volume	22
Online published	17 Aug 2023
DOIs	https://doi.org/10.1038/s41563-023-01651-9
Publication status	Published - Oct 2023

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title = "Achieving ultrahigh fatigue resistance in AlSi10Mg alloy by additive manufacturing",

abstract = "Since the first discovery of the fatigue phenomenon in the late 1830s, efforts to fight against fatigue failure have continued. Here we report a fatigue resistance phenomenon in nano-TiB2-decorated AlSi10Mg enabled by additive manufacturing. This fatigue resistance mechanism benefits from the three-dimensional dual-phase cellular nanostructure, which acts as a strong volumetric nanocage to prevent localized damage accumulation, thus inhibiting fatigue crack initiation. The intrinsic fatigue strength limit of nano-TiB2-decorated AlSi10Mg was proven to be close to its tensile strength through the in situ fatigue tests of a defect-free microsample. To demonstrate the practical applicability of this mechanism, printed bulk nano-TiB2-decorated AlSi10Mg achieved fatigue resistance more than double those of other additive manufacturing Al alloys and surpassed those of high-strength wrought Al alloys. This strategy of additive-manufacturing-assisted nanostructure engineering can be extended to the development of other dual-phase fatigue-resistant metals. {\textcopyright} 2023, The Author(s), under exclusive licence to Springer Nature Limited.",

author = "Chengyi Dan and Yuchi Cui and Yi Wu and Zhe Chen and Hui Liu and Gang Ji and Yakai Xiao and Han Chen and Mingliang Wang and Jun Liu and Lei Wang and Yang Li and Ahmed Addad and Ying Zhou and Siming Ma and Qiwei Shi and Haowei Wang and Jian Lu",

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doi = "10.1038/s41563-023-01651-9",

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TY - JOUR

T1 - Achieving ultrahigh fatigue resistance in AlSi10Mg alloy by additive manufacturing

AU - Dan, Chengyi

AU - Cui, Yuchi

AU - Wu, Yi

AU - Chen, Zhe

AU - Liu, Hui

AU - Ji, Gang

AU - Xiao, Yakai

AU - Chen, Han

AU - Wang, Mingliang

AU - Liu, Jun

AU - Wang, Lei

AU - Li, Yang

AU - Addad, Ahmed

AU - Zhou, Ying

AU - Ma, Siming

AU - Shi, Qiwei

AU - Wang, Haowei

AU - Lu, Jian

PY - 2023/10

Y1 - 2023/10

N2 - Since the first discovery of the fatigue phenomenon in the late 1830s, efforts to fight against fatigue failure have continued. Here we report a fatigue resistance phenomenon in nano-TiB2-decorated AlSi10Mg enabled by additive manufacturing. This fatigue resistance mechanism benefits from the three-dimensional dual-phase cellular nanostructure, which acts as a strong volumetric nanocage to prevent localized damage accumulation, thus inhibiting fatigue crack initiation. The intrinsic fatigue strength limit of nano-TiB2-decorated AlSi10Mg was proven to be close to its tensile strength through the in situ fatigue tests of a defect-free microsample. To demonstrate the practical applicability of this mechanism, printed bulk nano-TiB2-decorated AlSi10Mg achieved fatigue resistance more than double those of other additive manufacturing Al alloys and surpassed those of high-strength wrought Al alloys. This strategy of additive-manufacturing-assisted nanostructure engineering can be extended to the development of other dual-phase fatigue-resistant metals. © 2023, The Author(s), under exclusive licence to Springer Nature Limited.

AB - Since the first discovery of the fatigue phenomenon in the late 1830s, efforts to fight against fatigue failure have continued. Here we report a fatigue resistance phenomenon in nano-TiB2-decorated AlSi10Mg enabled by additive manufacturing. This fatigue resistance mechanism benefits from the three-dimensional dual-phase cellular nanostructure, which acts as a strong volumetric nanocage to prevent localized damage accumulation, thus inhibiting fatigue crack initiation. The intrinsic fatigue strength limit of nano-TiB2-decorated AlSi10Mg was proven to be close to its tensile strength through the in situ fatigue tests of a defect-free microsample. To demonstrate the practical applicability of this mechanism, printed bulk nano-TiB2-decorated AlSi10Mg achieved fatigue resistance more than double those of other additive manufacturing Al alloys and surpassed those of high-strength wrought Al alloys. This strategy of additive-manufacturing-assisted nanostructure engineering can be extended to the development of other dual-phase fatigue-resistant metals. © 2023, The Author(s), under exclusive licence to Springer Nature Limited.

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U2 - 10.1038/s41563-023-01651-9

DO - 10.1038/s41563-023-01651-9

M3 - RGC 21 - Publication in refereed journal

SN - 1476-1122

VL - 22

SP - 1182

EP - 1188

JO - Nature Materials

JF - Nature Materials

ER -

Achieving ultrahigh fatigue resistance in AlSi10Mg alloy by additive manufacturing

Abstract

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