Constitutive and fracture behaviour of additively manufactured aluminium
File(s)
Published version
Author(s)
Zhou, Jingsheng
Zhang, Ruizhi
Amraei, Mohsen
Gardner, Leroy
Type
Journal Article
Abstract
This paper presents a detailed experimental and numerical study into the constitutive and fracture behaviour of additively manufactured AlSi10Mg aluminium alloy produced by laser beam powder bed fusion (PBF-LB/M). A series of 26 coupons with various geometries (to achieve a range of stress states) and build directions (θ = 0°, 45° and 90° relative to the layer direction, to investigate anisotropy) were additively manufactured and tested. The PBF-LB/M AlSi10Mg material showed mild constitutive anisotropy, with the highest Young’s modulus and proof strengths observed for the 0° coupons. For the case of smooth round bars, an appreciable discrepancy in engineering fracture strain was observed between repeated tests on the 90° coupons, with up to almost 60% differences, indicating potential variability in defect density. Complementary finite element models were developed to extract fracture strains and stress states. The analysis showed minor anisotropy in the fracture properties, with two outliers in the 90° coupons that exhibited considerably higher fracture strains than the 0° coupons, attributed to good interlayer adhesion and a reduced defect density near the critical cross-section. Two ductile fracture criteria, namely the Positive Stress Triaxiality-Lode Angle Parameter Interaction Model (PTLIM) and the Lode angle Modified Void Growth Model (LMVGM), were calibrated against the test data and shown to achieve comparable predictive capabilities.
Date Issued
2026-08-10
Date Acceptance
2026-05-13
Citation
Engineering Fracture Mechanics, 2026, 343
ISSN
0013-7944
Publisher
Elsevier BV
Journal / Book Title
Engineering Fracture Mechanics
Volume
343
Copyright Statement
© 2026 The Author(s). Published by Elsevier Ltd. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).
License URL
Publication Status
Published
Article Number
112277
Date Publish Online
2026-05-17