Authors: Pankaj Kumar Rai, Dr. P. N. Ahirwar
Abstract: Additive manufacturing (AM) processes qualifies in producing high-performance, complex design component with an efficient use of material. However, processing of fusion based additive manufacturing processes such as Laser Powder Bed Fusion Processes (LPBF) generates thermal stresses due to rapid heating and cooling cycles. The accumulation of these residual stresses in the printed component is undesirable and may result in dimensional distortion, anisotropy, and premature failure of components during service. Aluminium alloys such as AlSi10Mg are processed through LPBF route of AM due its excellent printability and its application in aerospace applications due to its superior fly to weight ratio. However, the printed AlSi10Mg faces challenges due to its high thermal conductivity and residual stresses. These stresses hinder dimensional tolerances and worsen mechanical performance. This review provides the overview of additive manufacturing processes with the physics of residual stress development and residual stresses in AlSi10Mg. A detailed discussion on residual stress generation, measurement and management are presented. The residual measurement strategies involving destructive, semi-destructive, and non-destructive and state-of-the-art numerical modeling approaches, including finite element–based and data-driven methods. This review aims to provide a comprehensive insight of the residual stress in additively manufactured AlSi10Mg to help in designing of component for practical application.
DOI: http://doi.org/10.5281/zenodo.18279481
