Effects of substrate surface treatments on hybrid manufacturing of AlSi7Mg using die casting and selective laser melting  

作　　者：Haiyang Fan Ann Witvrouw Friedrich Wolf-Monheim Rainer Souschek Shoufeng Yang 

机构地区：[1]Department of Mechanical Engineering and Flanders Make,KU Leuven,Celestijnenlaan 300B,box 2420,Heverlee,B-3001 Leuven,Belgium [2]Ford Research & Advanced Engineering,Ford Research and Innovation Center Aachen,Süsterfeldstraße 200,52072 Aachen,Germany [3]Yantai Research Institute,Harbin Engineering University,264000 Yantai,China

出　　处：《Journal of Materials Science & Technology》2023年第25期142-156,共15页材料科学技术（英文版）

基　　金：financially supported by the Ford Motor Com-pany under Ford-KU Leuven University Research Alliance Frame-work KUL-0025 fortheproject‘Incremental Additive Manufacturing for Metal Applications’.Haiyang Fan also appreciates the financial support of the China Scholarship Council(CSC)(No.201606050132).

摘　　要：To balance the manufacturing cost and customizability of automotive parts,a hybrid manufacturing process combining die-casting and selective laser melting(SLM)is proposed:starting with a conventional cast substrate,SLM is utilized to add additional geometric elements on top of it.For this hybrid process,the first priority is to prepare a substrate surface suitable for the subsequent SLM addition of the top-on elements.In this study,the original cast surface of AlSi7Mg was processed by sandblasting,wire electro-discharge machining,and laser remelting,respectively.Then,additional AlSi7Mg components were built on both the original cast and treated surfaces through SLM.After hybrid builds,these surfaces and resultant interfaces were examined by optical and scanning electron microscopes.Results indicate that the defect-free metallurgical joint between the cast and additively added parts can be formed on all surfaces except for the one processed by electro-discharge machining.The observed epitaxial grain growth crossing the interface implies a strong connection between the cast and the SLMed component.Despite these benefits,also mismatches in microstructure,residual stress level and element distribution between the two parts are identified.After a comprehensive assessment,laser remelting with no additional machining is recommended as the optimal surface treatment preceding SLM fabrication,because of its user-friendly operation,low cost,and high industrial feasibility.

关 键 词：Hybrid manufacturing Aluminium alloy Surface treatment Laser remelting Interface Automotive 

分 类 号：TG146.21[一般工业技术—材料科学与工程] TG665[金属学及工艺—金属材料]