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Bogen Final 8 3 2020 with cert.pdf (15.4 MB)

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Effects of Manufacturing Defects on the Corrosion of Additively Manufactured AlSi10Mg

Bogen, Daniel J
http://rave.ohiolink.edu/etdc/view?acc_num=ysu1596641889374996

Abstract Details

2020, Master of Science in Engineering, Youngstown State University, Department of Civil/Environmental and Chemical Engineering.
As new influxes of aerospace technology are introduced, production of legacy system replacement parts is halted. For end-users of legacy systems, like the U.S. Air Force, selective laser melting (SLM) offers a unique solution to this problem by making highly specific and complex parts available without the lead time or cost associated with conventional acquisition methods. One major obstacle impeding full implementation of legacy aerospace parts is the need for understanding of failure behavior of 3D-printed metals. This knowledge is important in the development of quality control standards and maintenance protocols that ensure the safety of aircrafts in use. In this study, experiments were performed on AlSi10Mg to understand the corrosion behavior of this alloy in practical environments, when conceivable errors in fabrication result in defective parts. Three studies were performed to evaluate the effects of process parameters, defect size, and contamination levels of Inconel, on the corrosion behavior of AlSi10Mg. In the first study, galvanic corrosion was observed between α-aluminum and silicon coarsened in the heat-affected zone of characteristic SLM melt pools. In addition, a relationship between process parameters of laser power, laser velocity, and hatch spacing and corrosion was determined. In the second study, density of defects was determined to be a more pressing issue in the failure of corroded AlSi10Mg in an accelerated neutral salt fog. Finally, galvanic coupling between nickel and both aluminum and silicon was concluded to catastrophically accelerate the corrosion of the alloy.
Holly Martin, Ph.D. (Advisor)
Brett Conner, Ph.D. (Committee Member)
Pedro Cortes, Ph.D. (Committee Member)
277 p.
Aerospace Materials; Chemical Engineering; Engineering; Materials Science
Corrosion; Additive Manufacturing; Aluminum; Selective Laser Melting

Recommended Citations

Citations

  • Bogen, D. J. (2020). Effects of Manufacturing Defects on the Corrosion of Additively Manufactured AlSi10Mg [Master's thesis, Youngstown State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=ysu1596641889374996

    APA Style (7th edition)

  • Bogen, Daniel. Effects of Manufacturing Defects on the Corrosion of Additively Manufactured AlSi10Mg . 2020. Youngstown State University, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=ysu1596641889374996.

    MLA Style (8th edition)

  • Bogen, Daniel. "Effects of Manufacturing Defects on the Corrosion of Additively Manufactured AlSi10Mg ." Master's thesis, Youngstown State University, 2020. http://rave.ohiolink.edu/etdc/view?acc_num=ysu1596641889374996

    Chicago Manual of Style (17th edition)

ysu1596641889374996
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This open access ETD is published by Youngstown State University and OhioLINK.