AlSi10Mg, fabricated by the laser powder bed fusion (L-PBF) additive manufacturing process, offers many advantages compared to traditional cast material. In this study, its tensile properties are evaluated by investigating global and local deformation behavior via extensometer and strain gauge sensors. Samples are built using recycled AlSi10Mg powder on ProX-320 L-PBF equipment using vetted process parameters, as suggested by 3D Systems. The as-built samples contain a one-sided V-notch to precisely control the onset of failure. Strain gauges are installed near the notch region and the samples are tested on an MTS 50 kN electromechanical load frame.
The results show the L-PBF AlSi10Mg samples possess a large range of ultimate tensile and yield strengths. These mechanical performance inconsistencies highlight the need for appropriate and accurate monitoring systems for additively manufactured materials. In the elastic regime of each experiment, the strain recorded by strain gauge and extensometer increases both linearly and proportionally. Near failure, the strain gauge records higher strain in comparison to the extensometer due to its proximity to the notch tip. This deviation marks the beginning of plastic deformation. The strain gauge properly monitored and detected damage of the material prior to catastrophic failure. The experimental findings are also corroborated with finite element-based simulation results. In summary, this work establishes that strain gauge sensors can be used for online health monitoring of additively manufactured samples.
