Advanced additive manufacturing: Comparative analysis of mechanical properties of AlSi10Mg and Al2024-RAM2C

Additive manufacturing (AM) has revolutionized the production of high-performance components, particularly in industries like motorsport and aerospace. This study investigates the mechanical properties of AM-produced AlSi10Mg and introduces a novel Al2024-RAM2C alloy, designed to elevate the performance benchmarks of AM aluminum alloys in demanding environments. The Al2024-RAM2C alloy, formulated with patented reactive additive manufacturing (RAM) additions, showcases a suite of superior characteristics, including high tensile strength and enhanced fatigue resistance. However, the integration of this innovative alloy with AM processes necessitated meticulous parameter optimization efforts. Through comprehensive testing methodologies, the mechanical strength, impact toughness, and fatigue resistance in both axial and flexural bending loading of both AlSi10Mg and Al2024-RAM2C were carefully evaluated and further analyzed through FE-SEM microscopy. Results from these analyses revealed that while Al2024-RAM2C exhibited higher fatigue limits in axial loading and superior tensile strength, its impact toughness was significantly lower than that of AlSi10Mg. This comparative study clarifies the inherent strengths and limitations of the Al2024-RAM2C alloy relative to AlSi10Mg. The findings provide valuable insights into the performance characteristics of these materials, which can inform future developments in material design and manufacturing processes. This research contributes to the broader understanding of AM-enabled materials and their potential applications in producing lightweight, high-performance components for various industries.