Mechanical property improvements of LPBF-AlSi10Mg via forging to modify microstructure and defect characteristics

Additive Manufacturing (AM) processes have versatile capabilities but are susceptible to the formation of as-cast non-equilibrium microstructures, process-induced defects, and porosity, which have deleterious effects on the mechanical performance. As part of our NSF-ERC-HAMMER program, isothermal forging was investigated as a novel post-processing technique for refining microstructure, reducing process defect severity, and thereby improving mechanical properties. Specimens of Laser Powderbed Fusion (LPBF) AlSi10Mg were fabricated over a range of process parameters and tensile tested as a baseline. Initial work focused on duplicate AM material that was then hot forged with 20 % strain to investigate the effects of isothermal forging at one temperature and strain rate on the microstructure, tensile, and fatigue properties of the as-deposited materials. The microstructures, process-induced defect populations, and tensile/fatigue properties of both as-deposited and forged materials were quantified and analysed by OM, EBSD, XCT, and SEM by various NSF-ERC-HAMMER team members. Isothermal hot forging was found to induce recrystallisation and modify process-induced defect geometry along with increasing tensile ductility. The effects of AM deposition parameters and forge post-processing conditions on LPBF AlSi10Mg will be discussed in terms of microstructure, mechanical properties, and fractography.