Ruslan Balokhonov, Veronika Utyaganova, Diana Gatiyatullina, Aleksandr Zemlianov, Varvara Romanova

DOI Number
First page
Last page


Interfaces and surfaces play an important role in tribology, mechanics and materials science, causing plastic strain localization and stress concentration of different spatial scales. The interfacial inhomogeneity is highly pronounced in 3D printed materials due to thermo-cycling and layer-by-layer building. In this paper, the inlayer and interlayer structure of a eutectic Al-Si alloy fabricated by wire-feed electron-beam additive manufacturing is investigated by optical and electron microscopy. Model structures inheriting the experimental morphology are created, and their deformation and fracture are simulated using ABACUS/Explicit, with the user-defined subroutines being developed to describe the constitutive behavior of aluminum dendrite, silicon and eutectic materials. A two-scale computational approach is implemented to study the influence of the interlayer formed in the heat-affected zone on the dendritic structure strength.


Additive manufacturing, Aluminum alloys, Microstructure, Multiscale numerical simulation, Plastic deformation, Fracture

Full Text:



Ostermeyer, G.-P., Popov, V.L., Shilko, E.V., Vasiljeva O.S., 2021, Multiscale biomechanics and tribology of inorganic and organic systems, STME Springer, Cham, 565 p.

Goryacheva, I.G., Paggi, M., Popov, V.L., 2021, Editorial: Contact mechanics perspective of tribology, Frontiers in Mechanical Engineering, 7, 649792.

Balokhonov, R., Romanova, V., Schwab, E., Zemlianov, A., Evtushenko, E., 2021, Computational microstructure-based analysis of residual stress evolution in metal-matrix composite materials during thermomechanical loading, Facta Universitatis-Series Mechanical Engineering, 19, pp. 241-252.

Zhao, N., Parthasarathy, M., Patil, S., Coates, D., Myers, K., Zhu, H., Li, W., 2023, Direct additive manufacturing of metal parts for automotive applications, Journal of Manufacturing Systems, 68, pp. 368-375.

Herzog, D., Seyda, V., Wycisk, E., Emmelmann, C., 2016, Additive manufacturing of metals, Acta Materialia, 117, pp. 371-392.

Kaur, I., Singh, P., 2021, Critical evaluation of additively manufactured metal lattices for viability in advanced heat exchangers, International Journal of Heat and Mass Transfer, 168, 120858.

Wasono, R.S., Wahab, D.A., Azman, A.H., 2019, Additive manufacturing for repair and restoration in remanufacturing: An overview from object design and systems perspectives, Processes, 7, 802.

Kiani, P., Dupuy, A. D., Ma, K., Schoenung, J. M., 2020, Directed energy deposition of AlSi10Mg: Single track nonscalability and bulk properties, Materials & Design, 194, 108847.

Zolotorevsky, V.S., Belov, N.A., Glazoff, M.V., 2007, Casting aluminum alloys, Elsevier Ltd., Amsterdam, 544 p.

Apelian, D., 2009, Aluminum cast alloys: Enabling tools for improved performance, North American Die Casting Association, Wheel Illinois, 60 p.

Ye, H., 2003, An overview of the development of Al-Si-alloy based material for engine applications, Journal of Materials Engineering and Performance, 12, pp. 288-297.

Nowak, M., Hari-Babu, N., 2011, Novel grain refiner for hypo and hyper-eutectic Al-Si alloys, LMT 2011 Conf paper, Materials Science Form, 690, pp. 49-52.

Flemings, M.C., 1974, Solidification processing, Metallurgical and Materials Transactions, 5, pp. 2121-2134.

Abboud, J., Mazumder, J., 2020, Developing of nano sized fibrous eutectic silicon in hypereutectic Al–Si alloy by laser remelting, Scientific Reports, 10, pp. 1-18.

McDonald, S. D., Nogita, K., Dahle, A. K., 2004, Eutectic nucleation in Al-Si alloys, Acta Materialia, 52, pp. 4273-4280.

Chou, R., Milligan, J., Paliwal, M., Brochu, M., 2015, Additive manufacturing of Al-12Si alloy via pulsed selective laser melting, JOM: the journal of the Minerals, Metals & Materials Society, 67, pp. 590-596.

Siddique, S., Imran, M., Wycisk, E., Emmelmann, C., Walther, F., 2015, Influence of process-induced microstructure and imperfections on mechanical properties of AlSi12 processed by selective laser melting, Journal of Materials Processing Technology, 221, pp. 205-213.

Kim, D.-K., Hwang, J.-H., Kim, E.-Y., Heo, Y.-U., Woo, W., Choi, S.-H., 2017, Evaluation of the stress-strain relationship of constituent phases in AlSi10Mg alloy produced by selective laser melting using crystal plasticity FEM, Journal of Alloys and Compounds, 714, pp. 687-697.

Silva, A. D., Wang, S., Volpp, J., Kaplan, A.F.H., 2020, Vertical laser metal wire deposition of Al-Si alloys, Procedia CIRP, 94, pp. 341-345.

Huang, W., Chen, S., Xiao, J., Jiang, X., Jia, Y., 2021, Laser wire-feed metal additive manufacturing of the Al alloy, Optics & Laser Technology, 134, 106627.

Kolubaev, E., Rubtsov, V., Chumaevskii, A., Astafurova, E., 2022, Micro-, meso- and macrostructural design of bulk metallic and polymetallic materials by wire-feed electron-beam additive manufacturing, Physical Mesomechanics, 25, pp. 479-491.

Osipovich, K., Kalashnikov, K., Chumaevskii, A., Gurianov, D., Kalashnikova, T., Vorontsov, A., Zykova, A., Utyaganova, V., Panfilov, A., Nikolaeva, A., Dobrovolskii, A., Rubtsov, V., Kolubaev, E., 2023, Wire-feed electron beam additive manufacturing: A review, Metals, 13, 279.

Zhu, Z., Hu, Z., Seet, H.L., Liu, T., Liao, W., Ramamurty, U., Nai, S.M.L., 2023, Recent progress on the additive manufacturing of aluminum alloys and aluminum matrix composites: Microstructure, properties, and applications, International Journal of Machine Tools and Manufacture, 190,104047.

Balokhonov, R., Zemlianov, A., Utyaganova, V., Gatiyatullina, D., Romanova, V., 2023, Two-scale computational analysis of deformation and fracture in an Al-Si composite material fabricated by electron beam wire-feed additive manufacturing, Metals, 13, 1465.

Zemlyanov, A.V., Gatiyatullina, D.D., Utyaganova, V.R., Dymnich, E., Shamarin, N.N., Nikonov, S.Y., Romanova, V.A., Kulkov, A.S., Balokhonov, R.R., 2023, A study of deformation and fracture of the eutectic in an additively manufactured Al-Si composite alloy, Physical Mesomechanics, 26, pp. 678-690.

Wang, B.B., Xie, G.M., Wu, L.H., Xue, P., Ni, D.R., Xiao, B.L., Liu, Y.D., Ma, Z.Y., 2021, Grain size effect on tensile deformation behaviors of pure aluminum, Materials Science and Engineering: A, 820, 141504.

Wejrzanowski, T., Lewandowska, M., Kurzydłowski, K. J., 2010, Stereology of nano-materials, Image Analysis and Stereology, 29(1), pp. 1-12.


  • There are currently no refbacks.

ISSN: 0354-2025 (Print)

ISSN: 2335-0164 (Online)

COBISS.SR-ID 98732551

ZDB-ID: 2766459-4