Metal additive manufacturing is finding growing applicability in motorsports and high performance car sectors. Laser-Powder Bed Fusion (L-PBF) is the most developed AM technology for lightweight aluminum alloys producing near-net-shape components of complex geometry that achieve outstanding lightweight targets. A key issue in the widespread industrial acceptability of L-PBF is the structural integrity of these lightweight components when subjected to dynamic loading conditions because it requires in-depth knowledge of the fatigue behavior of L-PBF aluminum under the combined effect of stress gradients, residual stresses, surface condition and process-induced internal defects. This contribution overviews the presentation and application of an integrated design workflow that includes the following phases: i) a topological optimization phase to achieve lightweight targets, ii) a design for additive manufacturing phase supported by process simulation to optimize part production, iii) actual part fabrication in an industrial-grade L-PBF system using AlSi10Mg alloy powder followed by post fabrication heat treatment iv) production and fatigue testing of witness specimens providing relevant design data; v) fatigue testing of the parts to determine actual performance and vi) final assessment of the design know-how developed for fatigue-critical additively manufactured metal components.

Lightweight Design and Additive Manufacturing of a Fatigue-Critical Automotive Component / Nicoletto, G.; Riva, E.; Uriati, F.. - In: SAE TECHNICAL PAPER. - ISSN 0148-7191. - 1:(2022). [10.4271/2022-37-0026]

Lightweight Design and Additive Manufacturing of a Fatigue-Critical Automotive Component

Nicoletto G.
;
Riva E.;Uriati F.
2022

Abstract

Metal additive manufacturing is finding growing applicability in motorsports and high performance car sectors. Laser-Powder Bed Fusion (L-PBF) is the most developed AM technology for lightweight aluminum alloys producing near-net-shape components of complex geometry that achieve outstanding lightweight targets. A key issue in the widespread industrial acceptability of L-PBF is the structural integrity of these lightweight components when subjected to dynamic loading conditions because it requires in-depth knowledge of the fatigue behavior of L-PBF aluminum under the combined effect of stress gradients, residual stresses, surface condition and process-induced internal defects. This contribution overviews the presentation and application of an integrated design workflow that includes the following phases: i) a topological optimization phase to achieve lightweight targets, ii) a design for additive manufacturing phase supported by process simulation to optimize part production, iii) actual part fabrication in an industrial-grade L-PBF system using AlSi10Mg alloy powder followed by post fabrication heat treatment iv) production and fatigue testing of witness specimens providing relevant design data; v) fatigue testing of the parts to determine actual performance and vi) final assessment of the design know-how developed for fatigue-critical additively manufactured metal components.
Lightweight Design and Additive Manufacturing of a Fatigue-Critical Automotive Component / Nicoletto, G.; Riva, E.; Uriati, F.. - In: SAE TECHNICAL PAPER. - ISSN 0148-7191. - 1:(2022). [10.4271/2022-37-0026]
File in questo prodotto:
Non ci sono file associati a questo prodotto.

I documenti in IRIS sono protetti da copyright e tutti i diritti sono riservati, salvo diversa indicazione.

Utilizza questo identificativo per citare o creare un link a questo documento: https://hdl.handle.net/11381/2934440
Citazioni
  • ???jsp.display-item.citation.pmc??? ND
  • Scopus ND
  • ???jsp.display-item.citation.isi??? ND
social impact