A novel Tri-field coupling strategy for tailoring residual stress and mechanical properties in laser-powder bed fused AlSi10Mg alloy

Mitigating the detrimental residual stress (RS) inherent in laser powder bed fused (L-PBFed) AlSi10Mg alloys is crucial for ensuring dimensional stability and preventing premature component failure. In this study, a novel thermal-magnetic-vibration stress relief (TMVSR) method is proposed, and dual-field treatments, including thermal-vibration stress relief (TVSR), thermal-magnetic stress relief (TMSR), and magnetic-vibration stress relief (MVSR), together with the tri-field (TMVSR) treatment, are applied to an L-PBFed AlSi10Mg alloy. The results show that TMVSR achieved the highest RS relief rate of 69.7%, significantly outperforming dual-field methods (48.1%–53.5%). Moreover, the TMVSR-treated sample exhibits the greatest strengthening effect, with the yield and ultimate tensile strengths increasing by 19.88% and 6.99%, respectively, while maintaining good ductility. The synergistic effects and underlying mechanisms of thermal–magnetic–vibrational coupling on the RS and mechanical property tailoring in paramagnetic materials are systematically investigated. These findings extend the applicability of the TMSR and MVSR to paramagnetic alloys. They also demonstrate that the TMVSR is a promising approach for simultaneously controlling the residual stress and mechanical properties of additively manufactured metals.