Investigating the Microstructural and Mechanical Characteristics of Laser Additive‐Manufactured AlSi10Mg Specimens Through Experimental and Phase‐Field Modeling Approaches

Abstract

Metal‐based additive manufacturing can make complicated parts that are complex or expensive to cast and process. Rapid cooling rates increase L‐PBF’s mechanical properties during manufacturing. The objective of this study is to examine the impact of process parameters in the L‐PBF technique on the characteristics of microstructure and mechanical properties, specifically, on the nano‐hardness influenced by Si segregation. The microstructures of the produced specimens were examined using FESEM and the analysis identified the existence of bimodal equiaxed α‐Al grains, accompanied by Si phases located within their grain boundaries. In addition, the solidified sample exhibited the segregation of secondary precipitates, particularly , which resulted in enhanced mechanical properties. Both cellular walls and Si precipitates impede the motion and generation of dislocations, thereby influencing the overall behavior of dislocations. The examination of segregation at the top layer was conducted in a comprehensive manner, subsequently employing EDS for analysis. The presence of , , and other phases in all samples was confirmed through XRD. The as‐built samples’ residual stress under different process conditions was also investigated. In addition, a comparison was made between the obtained microstructure and a phase field model that was developed in order to forecast the evolution of the microstructure.This article is protected by copyright. All rights reserved.