Fatigue performance of 3D printed aluminium in corrosive environment

There is a need to understand how structural components of aluminium can withstand repeated mechanical loading in a corrosive environment. Examples can e.g. be found in the automotive industry where the current transition towards electric drivetrains is resulting in new structural components made from aluminium. It is crucial that these components can maintain their structural integrity in a relevant environment. Within this RISE project capacity and competence is developed to address communicated industrial needs.

Method

In this study 3D printed aluminium (AlSi10Mg) is studied. To include the impact of the surface properties both machined and as-printed specimens are tested. Three test sequences are used to quantify the impact on fatigue performance of the corrosive environment:

• Nominal: only mechanical loading
• Sequential: specimens are degraded in a corrosive environment (chamber testing) and then mechanically loaded
• Concurrent: specimens are subjected to cyclic mechanical loading while being in a corrosive environment

The accelerated corrosion testing is carried out according to VDA 233-102 but other test protocols are available. The fatigue testing is carried out at R=0.1.

Results

In total, six unique configurations are evaluated in terms of their fatigue performance (S-N curves). The goal of the study is to quantify how the nominal fatigue performance is reduced due to the corrosive environment (sequential and concurrent). In addition, the impact of the corrosive environment will be studied in terms of e.g. pit depths. Fractography will be carried out to study initiation and propagation mechanisms. Results will be disseminated through peer-reviewed articles (conference and/or journal).