SIM-AM 2025

Simulation Strategy for Heat-Treatment of Scalmalloy Components

  • QUAN, Dieu-Linh (Centre de Recherche en Aéronautique - CENAERO)
  • POLETZ, Nicolas (Centre de Recherche en Aéronautique - CENAERO)
  • JEAN-BAPTISTE, Marine (Centre de Recherches Métallurgiques - CRM)

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In aerospace industry, there is a need for maximization of load capacities together with minimization of energy consumption in air transport systems, pushing the use of materials with high mechanical properties and less specific weights. This makes Scalmalloy – a new aluminum alloy – become a perfect candidate for its exceptional property of high strength-to-weight ratio. Current research trend is focusing on optimizing additive manufacturing process, exploring the effects of process parameters on the micro-structures, porosity and mechanical properties of LPBF-fabricated Scalmalloy for the performance enhancement of high part density. There has been also significant research on heat-treated properties which are often provided by material suppliers and publications, but little work on work-hardening behaviour at elevated temperatures. These properties are important not only for performance analysis of component in service but also for post-build process Simulation. In this study, heat-treated properties at elevated temperatures and work-hardening behaviour are discussed. Next, ready-to-use equations as function of relative density and temperature are derived to calculate the “effective” material properties of Scalmalloy grid-support. Experiment results show that heat-treatment has increased 60% strength but reduced the ductility of Scalmalloy. Estimated “effective” properties are applied for the simulation of impeller with grid-supports. About 50% of residual stress was relieved on the heat-treated part, revealing that this post-build process also plays a role as stress relief. All results including experimental, derived equations and simulation results are observed to be in good agreement with reference solutions. The goal of the study is to offer an efficient approach, facilitating the simulation to get first-time-right Scalmalloy parts.