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Thermal-magnetic stress relief induced evolution of residual stress and mechanical properties in selectively laser melted AlSi10Mg alloy.

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Title: Thermal-magnetic stress relief induced evolution of residual stress and mechanical properties in selectively laser melted AlSi10Mg alloy.
Authors: Gao, Zhiying1 (AUTHOR), Song, Hechuan1,2 (AUTHOR), Zhang, Boyang1,2 (AUTHOR), Zhang, Qingdong1,2 (AUTHOR) zhang_qd@me.ustb.edu.cn
Source: Materials Science & Engineering: A. May2026, Vol. 959, pN.PAG-N.PAG. 1p.
Subjects: Residual stresses, Aluminum-magnesium-silicon alloys, Precipitation hardening, Microstructure, Dislocations in crystals, Mechanical behavior of materials, Selective laser melting
Abstract: The selective laser melting (SLM) process induces substantial residual stresses in AlSi10Mg alloys, which significantly compromise dimensional stability and service performance. To achieve efficient and low-energy residual stress relief without degrading mechanical properties, a novel thermal–magnetic stress relief (TMSR) treatment was proposed in this study. However, limited research has explored its effects and control mechanisms in paramagnetic materials. Here, the influences of thermal stress relief (TSR), magnetic stress relief (MSR), and TMSR on the residual stress, mechanical properties, and microstructure of SLM-fabricated AlSi10Mg samples were systematically investigated. A residual stress evolution model was established to elucidate the mechanism by which TMSR regulates stress relaxation. The results indicate that TMSR preserves the eutectic Si network while promoting nano-Si precipitation and dislocation multiplication. The average residual stress was reduced by 50.9%, accompanied by improved stress uniformity, owing to the synergistic effects of high-temperature–induced dislocation thermal activation, reduced dislocation nucleation energy and motion resistance from the magnetoplastic effect, and nanoscale Si precipitation. Furthermore, a strength model was developed, which quantitatively revealed that the enhancements in yield strength, ultimate tensile strength, and elongation along the building direction mainly originated from precipitation strengthening and dislocation strengthening. This study provides fundamental insights into stress relaxation, mechanical property enhancement, dislocation evolution, and precipitation behavior in paramagnetic materials under thermal-magnetic coupling effects. [ABSTRACT FROM AUTHOR]
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Database: Engineering Source
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Abstract:The selective laser melting (SLM) process induces substantial residual stresses in AlSi10Mg alloys, which significantly compromise dimensional stability and service performance. To achieve efficient and low-energy residual stress relief without degrading mechanical properties, a novel thermal–magnetic stress relief (TMSR) treatment was proposed in this study. However, limited research has explored its effects and control mechanisms in paramagnetic materials. Here, the influences of thermal stress relief (TSR), magnetic stress relief (MSR), and TMSR on the residual stress, mechanical properties, and microstructure of SLM-fabricated AlSi10Mg samples were systematically investigated. A residual stress evolution model was established to elucidate the mechanism by which TMSR regulates stress relaxation. The results indicate that TMSR preserves the eutectic Si network while promoting nano-Si precipitation and dislocation multiplication. The average residual stress was reduced by 50.9%, accompanied by improved stress uniformity, owing to the synergistic effects of high-temperature–induced dislocation thermal activation, reduced dislocation nucleation energy and motion resistance from the magnetoplastic effect, and nanoscale Si precipitation. Furthermore, a strength model was developed, which quantitatively revealed that the enhancements in yield strength, ultimate tensile strength, and elongation along the building direction mainly originated from precipitation strengthening and dislocation strengthening. This study provides fundamental insights into stress relaxation, mechanical property enhancement, dislocation evolution, and precipitation behavior in paramagnetic materials under thermal-magnetic coupling effects. [ABSTRACT FROM AUTHOR]
ISSN:09215093
DOI:10.1016/j.msea.2026.149993