Effects of Selective Laser Melting Parameters on Relative Density of AlSi10Mg

Abstract

Abstract-Selective Laser Melting (SLM) is an advance Additive Manufacturing (AM) technique in which a component is manufacturing in a layer by layer manner by melting the top surface of a powder bed with a high intensity laser according to sliced 3D CAD data. AlSi10Mg alloy is a traditional cast alloy that is often used for die-casting. Because of its good mechanical and other properties, this alloy has been widely used in the automotive industry. In this work, the effects on the relative density is investigated for SLM-produced AlSi10Mg parts on one factor at a time (OFAT) basis by keeping constant various parameters such as laser power, scanning speed and hatching distance. It is shown that AlSi10Mg parts produced by SLM having best relative density values are at 350 watt laser power, 1650 mm/s of scanning speed and hatching distance of 0.13mm.

Optimization of Laser Powder Bed Fusion Processing Using a Combination of Melt Pool Modeling and Design of Experiment Approaches: Density Control

“…There are currently two main ways to realize this process optimization for new alloys. Most often, this optimization is carried out by defining an experiment plan that covers different arrangements of laser power, scanning speed, hatching space, layer thickness, scanning strategy and part orientation for a given alloy [3][4][5][6][7][8][9][10]. Once the specimens are printed, their mechanical properties are evaluated and a conclusion is drawn on the influence of the different processing parameters on the final part geometric and service attributes.…”

“…To print components with a material density ≥99.8% and a maximum allowable build rate of BR = 15 cm 3 /h (Figure 9), the corresponding volumetric laser energy density corresponds to E = 67 J/mm 3 (see the dot in Figure 9c). Since t = 40 µm and h = 110 µm, the remaining LPBF parameters can easily be defined using the energy density and build rate definitions of Equations (7) and (8): laser power~285 W and scanning speed~960 mm/s [36]. Note that even though this combined modeling-experiment approach was validated for only one specific LPBF system (EOS M 280), we hypothesize that it can be extended to any LPBF system, provided an adequate calibration experiment is carried out.…”

The Effect of Stress Relief on the Mechanical and Fatigue Properties of Additively Manufactured AlSi10Mg Parts

“…This behavior was also observed by Calignano [17], where they also determined that stress relief led to a decline the density and mechanical properties of the specimen. Ahmed [5] determined that the greatest challenge in producing aluminum alloys parts by SLM technique was to minimize porosity, which is the major effect of the relative density as aluminum alloys are easily subjects to oxidation during processing, stimulating pore formation. Therefore, more research is needed to address the impact of heat treatment temperatures on the properties of the SLM produced samples in order to optimize the properties for intended applications [18].…”

“…Silicon based aluminum alloys such as AlSi10Mg, AlSi12, etc. are currently used for laser AM and these are characterized by good castability, low shrinkage and moderately low melting temperature and AlSi10Mg is one of the most common alloys characterized with a hypoeutectic composition [5,6]. Prashanth et al [7] studied the heat treatment of hypereutectic Al-Si alloys, which are said to have a wide application in the automobile and aerospace sectors due to their high wear and corrosion resistance.…”

Heat treatment influences densification and porosity of AlSi10Mg alloy thin-walled parts manufactured by selective laser melting technique

“…Raus et al [18] investigated the densification of 99.13% for AlSi10Mg specimens in the AB condition, and the densification is further enhanced to 99.80% by remelting of each layer with the same processing parameters. In another study, they were obtained the relative densities of 99.26% and 99.34% with optimal combinations of laser power, scanning speeds and hatch spacings [19,20].…”