Combinatorial synchrotron diffraction-constitutive modelling-crystal plasticity simulation framework for direct metal laser sintered AlSi10Mg alloy

Combinatorial synchrotron and electron backscatter diffraction experiments coupled with constitutive modelling and fast Fourier transform crystal plasticity simulations have been employed to capture the mechanical behaviour of direct metal laser sintered AlSi10Mg alloy for different microstructures obtained by heat treatment. The microstructure of the as-printed sample with Al-Si eutectic cellular network transforms to coarse silicon particles on solutionising treatment at 510 degrees C for 1 h along with decrease in dislocation density that contributes to a decrease in strength and increase in ductility post solution heat treatment. Ageing of the solutionised specimen at 160 degrees C for 6 h leads to reprecipitation of silicon and improvement in strength with little change in ductility. The deformation behaviour at different length scales is captured by synchrotron diffraction and EBSD, while constitutive modelling using the Kocks-Mecking approach provides a mechanistic perspective on strain hardening of the alloy. Crystal plasticity simulations using fast Fourier transform solver are able to capture stress and strain hot spots in the as printed cellular and post solution treated non-cellular microstructures and provide information on the stress and strain evolution in the microstructure. A high throughput experimental and computational modelling protocol is established in the present investigation that can help rapidly screen different microstructures to establish processing-microstructure-mechanical property paradigm in direct metal laser sintered AlSi10Mg.

Automated summary

Combinatorial synchrotron and electron backscatter diffraction experiments, constitutive modelling, and fast Fourier transform crystal plasticity simulations were used to study the mechanical behavior and microstructure of direct metal laser sintered AlSi10Mg alloy. Heat treatment was found to change the microstructure and affect the strength and ductility of the alloy. Computational simulations successfully captured the stress and strain distribution, providing valuable insights into the mechanical behavior.