In the present study, AlSi10Mg samples produced by selective laser melting (SLM) were studied. Samples were machined from two types of bars obtained through different methods: either single laser (SL) or multiple laser (ML) machine setup. The bars were built perpendicular to the platform, which was pre-heated at 150 °C (working temperature), up to a height of 300 mm. The effect of the distance from the platform on the mechanical properties was investigated through tensile samples in as-built condition and after unconventional heat treatments (U-HT). Tensile strength changed by 80 MPa along the Z-axis (build direction) for SL case and by 100 MPa for ML case in the as-built samples. Vickers microhardness revealed an analogous gradient. This was correlated to a gradient in intra-granular precipitates' distribution along the Z-axis, as revealed by scanning electron microscopy (SEM). An unconventional heat treatment at 175 °C for 6h slightly improves the mechanical strength; higher temperature treatments at 200 and 225 °C for the same duration cause a progressive decrease in strength with an increase in elongation. The amount and size of the precipitates and the thickness of eutectic Si change with the heat treatment temperature, justifying the mechanical behavior.

Laser powder bed fusion (L-PBF) is an additive manufacturing technology that is gaining increasing interest in aerospace, automotive and biomedical applications due to the possibility of processing lightweight alloys such as AlSi10Mg and Ti6Al4V. Both these alloys have microstructures and mechanical properties that are strictly related to the type of heat treatment applied after the L-PBF process. The present review aimed to summarize the state of the art in terms of the microstructural morphology and consequent mechanical performance of these materials after different heat treatments. While optimization of the post-process heat treatment is key to obtaining excellent mechanical properties, the first requirement is to manufacture high quality and fully dense samples. Therefore, effects induced by the L-PBF process parameters and build platform temperatures were also summarized. In addition, effects induced by stress relief, annealing, solution, artificial and direct aging, hot isostatic pressing, and mixed heat treatments were reviewed for AlSi10Mg and Ti6AlV samples, highlighting variations in microstructure and corrosion resistance and consequent fracture mechanisms.

The present study analyzed the microstructure and the mechanical properties of AlSi10Mg SLMed bars (10 × 10 × 300 mm) and billets (10 × 100 × 300 mm) before and after the direct aging at 200 °C for 4 h and the T6 heat treatment. The discussed results are compared to those obtained by the AlSi10Mg samples manufactured with the same geometry but using different process parameters (layer thickness higher than 40 μm and a hatch spacing lower than 100 μm) and also through the Quality Index (QI). These work conditions allow the obtaining of a microstructural variation and different tensile properties in as-built top samples. In both batches, the cycle time was 45 h and together with the preheated build platform at 150 °C, induced an increase of UTS (Ultimate Tensile Strength) and yield strength on the bottom rather than the top samples due to the aging phenomena. Upon completion of the direct aging heat treatment, the effects induced by the platform were cancelled, keeping a full cellular microstructure that characterized the as-built SLMed (Selective Laser Melted) samples. Moreover, the Considère criterion and the work hardening analysis showed that the failure occurs after the necking formation in some of the T6 heat-treated samples. In this last case, the Si eutectic network globularized into Si particles, causing a decrease of UTS (from around 400 MPa to 290 MPa) in favour of an increase of ductility up to 15% and reaching a QI in the range 400 ÷ 450 MPa. These values place these samples between the high-quality aluminium cast alloy and T6 heat-treated ones.

Laser powder bed fusion is an additive manufacturing process characterized by different advantages like the manufacture of samples with complex geometry without the use of tools and/or molds. Generally, the manufactured samples are characterized by high tensile strengths which, however, can be affected by the presence of defects due to the unoptimized process parameters. In a large applications field, a low density of the as-built AlSi10Mg samples is a very important parameter to considered, e.g., due to both the loss of the tensile strengths correlated with a premature failure of the samples and the increase in time and costs associated with the manufacturing process. In addition, different post-process heat treatments can increase these effects leading to an ineffective manufacturing process. In this scenario, the present work shows the analysis of spherical and lack-of-fusion pores induced by the laser powder bed fusion process on the AlSi10Mg samples and their variations after different heat treatments (direct aging and T6). At the same time, the influence of pores on the Vickers microhardness and the tensile properties has been studied in the same AlSi10Mg samples (bars and billets) that were printed with single- and double-laser machine setup. Different process parameters were also analyzed and compared. The study was supported by the microstructural and pore analysis performed by optical microscopy along the XZ plane (build direction) and the XY plane. Finally, the greatest effects of pores were observed on the Vickers microhardness values; in fact, two different relationships between microhardness and density variation are discussed. The T6 heat treatment leads to a rounding of the pores already formed in the as-built samples and to a formation of new small pores. Graphical Abstract

The artificial aging heat treatments performed directly on as-built and solubilized AlSi7Mg0.6 and AlSi10Mg0.3 samples were characterized and discussed. The analysed bars and billets (height of 300 mm) were manufactured via the Laser Powder-Bed Fusion process on a build platform heated at 150 °C. Therefore, its influence on the as-built samples was studied in terms of mechanical performance variations between the bottom and top regions. Vickers microhardness measurements were performed to obtain aging profiles after direct aging (175–225 °C) and T6 heat treatments and to highlight better time and temperature parameters to optimize the mechanical properties of both alloys. SEM observations were used to characterize the microstructure before and after the heat treatments and its influence on the fracture mechanisms. Generally, the direct aging heat treatments show the same effects on both aluminium alloys, unlike the solubilization at 505 °C followed by artificial aging at 175 °C. The strengths vs. elongation values obtained after the direct aging treatments are better than those exhibited by T6 as highlighted by the quality index.

It is know that rapid solidification promotes solid solubility larger than at equilibrium, in association with very fine grains and eutectic microstructures. Consequently, the precipitation behaviour in additive manufacturing alloys can be quite different from that of alloys quenched after a solution treatment and aged. In this study, Al10SiMg samples were produced by Selective Laser Melting (SLM) while keeping the table at 150°C continuously during the job. The effect of temperature on mechanical properties of the samples was investigated as function of time or distance along the built axis (300 mm). The hardness behaviour was measured by micro Vickers indentations and significant inhomogeneities were detected along the built axes. These results were also confirmed by tensile property values. The tensile strength varied of 80 MPa from the bottom to the top of the sample. The microstructure was investigated by optical and scanning electron microscopy; the observations showed variable precipitate distributions that justify the mechanical response along the built axis.

Friction stir processing (FSP) has confirmed its valuable contribution to refining microstructures and the improvement of mechanical properties for Mg-Al alloys. Reference papers illustrate that post-processing aging treatments enhance hardness, but with the application of a solution heat treatment prior to FSP. In this work, aging was performed at two different temperatures (170 and 300 °C) directly on friction stir processed samples of AZ91 produced using high pressure die casting (HPDC). High rotational speeds of the tools (2500 and 3000 rpm) increases the heat input and the temperature of the plates during the process up to 270 °C. Vickers microhardness (HV) increased by 15–20% in the nugget, compared to the as FSPed condition; moreover, a greater homogeneity of hardness values was found at the higher aging temperature used. The β-Mg17Al12 precipitates are randomly distributed inside grains of the stirred area, while in the thermomechanical affected zone (TMAZ) they have grown in a network similar to the old eutectic. A preliminary investigation of FSPed samples deformed at 300 °C found that an equivalent hardness increase is achievable using hot deformation due to dynamic precipitation; to find local homogeneity in hardness, it is worth performing a final aging.

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