Main defects observed in aluminum alloy parts produced by SLM: From causes to consequences

Galy, Cassiopée; Guen, Emilie Le; Lacoste, Éric; Arvieu, Corinne

doi:10.1016/j.addma.2018.05.005

Cited by 161 publications

(122 citation statements)

References 59 publications

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“…The relative density of the Al6061 parts show lower values compared to those detected in AlSi10Mg, due to lower Si content, which increases the CTE, and causes the formation of hot cracks inside the as-built Al6061 parts. 4. The surface topology is significantly affected by the energy density applied to both materials.…”

Section: Summary and Conclusion 406mentioning

confidence: 99%

“…The average size of these spherical pores tends to grow by more than 20 µm at 65 J/mm 3 as illustrated in Figure 4(c, f). The mechanism of pore formation at high fusion rates might be related to the pores existing inside the gas atomized powder particles [4]. They may also result from the balling phenomena where the melted powder failed to wet the previously deposited layer [26].…”

Section: Relative Densitymentioning

confidence: 99%

“…The quality of Al alloys produced by SLM could be influenced by the chemical composition and CTE of the material used. Galy et al [4] showed that porosity, hot cracking, anisotropy, and surface quality are the principal defects of Al alloy parts. They also demonstrated that selection of SLM process parameters and the laser beam energy loss due to Al reflectivity are the primary causes of porosity and hot crack formation.…”

Section: Introductionmentioning

confidence: 99%

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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

Maamoun¹,

Xue²,

Elbestawi³

et al. 2018

Preprint

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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 satisfy the part 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) is 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 the AlSi10Mg and Al6061 alloys needed to achieve “optimum” values for each performance characteristic. A process map is 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. The second part of this study investigates the effect of SLM process parameters on the microstructure and mechanical properties of the same Al alloys. This comprehensive study is also aimed at reducing the amount of post-processing needed.

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Section: Summary and Conclusion 406mentioning

confidence: 99%

Section: Relative Densitymentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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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

Maamoun¹,

Xue²,

Elbestawi³

et al. 2018

Preprint

View full text Add to dashboard Cite

show abstract

“…Selective laser melting (SLM) is a kind of state‐of‐the‐art processing technology that manufactures components in an incremental layer‐by‐layer means using the laser to melt, bond, and solidify powder particles on powder bed . It has been widely used in the production of a variety of alloys including titanium alloys, aluminum alloys, and stainless steel, providing the possibility for its application in producing tungsten. Tan et al .…”

Section: Introductionmentioning

confidence: 99%

Selective Laser Melting and Remelting of Pure Tungsten

et al. 2020

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The processing of pure tungsten encounters a substantial challenge due to its high melting point and intrinsic brittleness. Selective laser melting (SLM) technique is gaining popularity and offers an excellent processing approach for refractory metals. Herein, dense pure tungsten specimens are produced by optimizing SLM processing parameters. The mechanical property of the SLM‐produced tungsten with an ultimate compressive strength of about 1200 MPa, which is obviously superior to that reported in other literature, is achieved. The increased laser energy input is instrumental in raising density and surface roughness of tungsten specimens. Interestingly, additional remelting of processed layers during SLM improves the surface quality and the microstructure and achieves the highest relative density (98.4% ± 0.5%). After laser remelting, the surface roughness is reduced by 28% and a large number of fine grains are obtained. The flow of fluids caused by remelting plays a decisive role in the formation of fine grains and the defect level. Therefore, these findings offer a new insight into SLM of pure tungsten.

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“…The differences, including defects, can be contributed to the high-energy density applied in the SLM building process, fast heating and cooling rates and the additive character of process [6]. The main defects observed in the SLM processed materials are porosities, cracking, anisotropy and poor surface finish [7].…”

Section: Selective Laser Melting Of Electrical Steelmentioning

confidence: 99%

Electrical Resistivity of Additively Manufactured Silicon Steel for Electrical Machine Fabrication

Tiismus

Kallaste

Vaimann

et al. 2019

2019 Electric Power Quality and Supply Reliability Conference (PQ) &Amp; 2019 Symposium on Electrical Engineering and Mechatron

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Additive manufacturing, commonly labeled as 3D printing is an essential component of the next industrial revolution, enabling both unprecedented fabrication freedom and streamlined production and logistics. Traditionally, the electrical machine cores are stacked from varnished soft magnetic laminations, which deliver reduced eddy and hysteresis losses during machine operation. Presently, dedicated metal printing platforms can produce industrial grade homomaterial metal components, promoting the fabrication of machines with highly complex topologies, but also increasing the eddy current induced in these components, due to lack of laminated structure. In this paper, we present experimental resistivity measurement results of 3% and 6.5% silicon content steel fabricated with selective laser melting.

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Main defects observed in aluminum alloy parts produced by SLM: From causes to consequences

Cited by 161 publications

References 59 publications

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

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

Selective Laser Melting and Remelting of Pure Tungsten

Electrical Resistivity of Additively Manufactured Silicon Steel for Electrical Machine Fabrication

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