Effect of SLM Process Parameters on the Quality of Al Alloy Parts; Part I: Powder Characterization, Density, Surface Roughness, and Dimensional Accuracy

Maamoun, Ahmed; Xue, Yi; Elbestawi, M.A.; Veldhuis, Stephen C.

doi:10.20944/preprints201811.0025.v1

Cited by 50 publications

(3 citation statements)

References 28 publications

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“…ASTM F3049-14 was used to examine the fresh powder of AlSi10Mg and Al6061 after sieving using a 75 µm mesh. The full powder characterization of the same powders used in this study was reported by Maamoun et al [15,16]. Particle size distribution test showed a particle size ranges from 12 to 120 µm for Al6061 and from 12 to 110 µm for AlSi10Mg.…”

Section: Methodssupporting

confidence: 56%

On the Effect of Selective Laser Melting Process Parameters on the Microstructure and Mechanical Properties of Al Alloys

Maamoun¹,

Xue²,

Elbestawi³

et al. 2018

Preprint

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Additive manufacturing (AM) offers customization of microstructure and mechanical properties of fabricated components according to the material selected, and process parameters applied. Selective laser melting (SLM) is the commonly used technique for processing high strength aluminum alloys. Selection of SLM process parameters could control the microstructure of parts and their mechanical properties. However, the process parameters limit and defects obtained inside the as-built parts present obstacles to customized part production. This study investigates the influence of SLM process parameters on the quality of as-built Al6061 and AlSi10Mg parts according to the mutual connection between the microstructure characteristics and mechanical properties. The microstructure of both materials was characterized for different parts processed over a wide range of SLM process parameters. The optimized SLM parameters were investigated to eliminate the internal microstructure defects. The behaviour of mechanical properties of parts was presented through regression models generated from the design of experiment (DOE) analysis for the results of hardness, ultimate tensile strength, and yield strength. A comparison between the results obtained and that reported in the literature is presented to illustrate the influence of process parameters, build environment, and powder characteristics on the quality of parts produced. The results obtained from this study could help to customize the part’s quality by satisfying their design requirements in addition to reducing the as-built defects which in turn reduce the amount of the post-processing needed.

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Section: Methodssupporting

confidence: 56%

On the Effect of Selective Laser Melting Process Parameters on the Microstructure and Mechanical Properties of Al Alloys

Maamoun¹,

Xue²,

Elbestawi³

et al. 2018

Preprint

Self Cite

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“…The current study represents a comprehensive work that investigates the effect of SLM process parameters on the relative density, surface roughness, and dimensional accuracy of as-built AlSi10Mg and Al6061 parts [38]. A full characterization of both materials’ powders was presented.…”

Section: Discussionmentioning

confidence: 99%

Effect of Selective Laser Melting Process Parameters on the Quality of Al Alloy Parts: Powder Characterization, Density, Surface Roughness, and Dimensional Accuracy

et al. 2018

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Additive manufacturing (AM) of high-strength Al alloys promises to enhance the performance of critical components related to various aerospace and automotive applications. The key advantage of AM is its ability to generate lightweight, robust, and complex shapes. However, the characteristics of the as-built parts may represent an obstacle to the satisfaction of the parts’ quality requirements. The current study investigates the influence of selective laser melting (SLM) process parameters on the quality of parts fabricated from different Al alloys. A design of experiment (DOE) was used to analyze relative density, porosity, surface roughness, and dimensional accuracy according to the interaction effect between the SLM process parameters. The results show a range of energy densities and SLM process parameters for AlSi10Mg and Al6061 alloys needed to achieve “optimum” values for each performance characteristic. A process map was developed for each material by combining the optimized range of SLM process parameters for each characteristic to ensure good quality of the as-built parts. This study is also aimed at reducing the amount of post-processing needed according to the optimal processing window detected.

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“…Zena J Wally et al (2018) utilised the SLM procedure to create a variety of titanium micro-lattice structures using Ti-6Al-V [20]. Ahmed H et al (2018) conducted a complete experimental investigation for evaluating the outcome of SLM process parameters on the quality of the manufactured Al alloys [21]. Jan Plat et al (2020) explained that the so-called volumetric energy density (VED) can be calculated by using hatch distance and scan speed and by plugging in the laser powder, as well as by using layer thickness; such calculations would allow the SLM process to be regulated [10].…”

Section: Introductionmentioning

confidence: 99%

Selective laser melting of Inconel 601 alloy using nanosecond fibre laser

Hadi¹,

Taha²

2022

PEN

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The paper describes the impact of selective laser melting factors including using a nanosecond fibre laser, including laser powers, scanning speed, and thickness of layer, on the relative density and micro hardness Vickers of IN 601 samples was studied. Selective laser melting (SLM) is a commonly used powder bed fusion metal additive manufacturing (AM). Recent advances in additive manufacturing have attracted significant industrial interest, especially for producing metallic parts. Scanning electron microscopy (SEM), EDX and other techniques were utilized for studying the effect of speed of scanning and power of laser on densification behaviour, microstructural evolution and micro hardness of Inconel v alloy that was processed by SLM. With a VED of 3200 J/mm 3 , a scan speed of 250 mm/s with a 80 W, micro cracks of about 79-93 µm and voids of about (4.5 µm -5.7) µm in diameter were realised. Moreover, the best hardness of 394 HV was attained with 80 W laser power. However, increasing the energy to more than the required values increased the porosity and decreased hardness. Using microsecond laser in SLM leads to the achievement of full density (almost 99.5%), whereas using nanosecond laser allows the achievement of less density (75-95%), which will be very useful for functions that require a porous structure and less weight, such as those in the aerospace applications, automotive industry and so on.

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Effect of SLM Process Parameters on the Quality of Al Alloy Parts; Part I: Powder Characterization, Density, Surface Roughness, and Dimensional Accuracy

Cited by 50 publications

References 28 publications

On the Effect of Selective Laser Melting Process Parameters on the Microstructure and Mechanical Properties of Al Alloys

On the Effect of Selective Laser Melting Process Parameters on the Microstructure and Mechanical Properties of Al Alloys

Effect of Selective Laser Melting Process Parameters on the Quality of Al Alloy Parts: Powder Characterization, Density, Surface Roughness, and Dimensional Accuracy

Selective laser melting of Inconel 601 alloy using nanosecond fibre laser

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