|About this Abstract
||7th World Congress on Integrated Computational Materials Engineering (ICME 2023)
||MPMD ICME Industry Implementation Award: Multi-scale Approach for Developing a High Silicon Al-Si-Cu Alloy for Additive Manufacturing Supercharger Rotors
||Andrew Bobel, Yoojin Kim, Lee Casalena, Anil Sachdev
|On-Site Speaker (Planned)
A computational alloy design approach was used to identify a hypereutectic Al-Si-Cu alloy suitable for processing by laser powder bed fusion (LPBF). The approach was to utilize the fast-cooling rates provided by additive manufacturing to produce nm-sized Si for in-situ particle reinforcement and Cu precipitates for room temperature strengthening. Feasibility of potential compositions was determined from melt-spinning experiments to mimic rapid solidification of LPBF. The selected alloy demonstrated a large printability range with consolidation >99.97% density. Transmission electron microscopy confirmed the formation of the predicted nano-Si particles and Al2Cu precipitation. Elevated uniaxial tensile properties and fully reversed high cycle fatigue (1e7) show superior strengths compared to commercial AlSi10Mg across all test temperatures up to 300 oC. Supercharger vanes were designed for the complexity afforded by additive manufacturing with 50% mass savings. The printed vanes were tested in a supercharger assembly on a dynamometer running a COPO LSX 350 SC engine.