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

Nat Mater. 2023 Oct;22(10):1182-1188. doi: 10.1038/s41563-023-01651-9. Epub 2023 Aug 17.

Authors

Chengyi Dan^#^{1

2}, Yuchi Cui^#¹, Yi Wu^#², Zhe Chen^#^{3

4}, Hui Liu⁵, Gang Ji⁶, Yakai Xiao², Han Chen², Mingliang Wang¹, Jun Liu², Lei Wang², Yang Li², Ahmed Addad⁶, Ying Zhou², Siming Ma², Qiwei Shi², Haowei Wang^{1

2}, Jian Lu^{7

8

9}

Affiliations

¹ State Key Laboratory of Metal Matrix Composites, Shanghai Jiao Tong University, Shanghai, People's Republic of China.
² School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai, People's Republic of China.
³ State Key Laboratory of Metal Matrix Composites, Shanghai Jiao Tong University, Shanghai, People's Republic of China. zhe.chen@sjtu.edu.cn.
⁴ School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai, People's Republic of China. zhe.chen@sjtu.edu.cn.
⁵ Department of Mechanical Engineering, City University of Hong Kong, Kowloon, People's Republic of China.
⁶ Univ. Lille, CNRS, INRA, ENSCL, UMR 8207-UMET-Unité Matériaux et Transformations, Lille, France.
⁷ Department of Mechanical Engineering, City University of Hong Kong, Kowloon, People's Republic of China. jianlu@cityu.edu.hk.
⁸ Centre for Advanced Structural Materials, City University of Hong Kong Shenzhen Research Institute, Greater Bay Joint Division, Shenyang National Laboratory for Materials Science, Shenzhen, People's Republic of China. jianlu@cityu.edu.hk.
⁹ CityU-Shenzhen Futian Research Institute, Shenzhen, People's Republic of China. jianlu@cityu.edu.hk.

^# Contributed equally.

PMID: 37592031
DOI: 10.1038/s41563-023-01651-9

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.

Abstract

Grants and funding