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

Abstract

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.

Effect of Blasting Treatments on the Surface Topography and Cell Adhesion on Biodegradable FeMn‐Based Stents Processed by Laser Powder Bed Fusion

“…[32,37] It will introduce residual compressive stress in the component surface due to plastic deformation, which has a positive effect on, e.g., hardness, fatigue, and tensile strength, as seen for other bulk materials. [41,42] Pure iron stents are known for their low degradation rates. However, addition of 30 wt% manganese increases the degradation rate in vitro up to %70%.…”

“…[ 32,37 ] It will introduce residual compressive stress in the component surface due to plastic deformation, which has a positive effect on, e.g., hardness, fatigue, and tensile strength, as seen for other bulk materials. [ 41,42 ]…”

Archives of Metallurgy and Materials

“…Moreover the aluminum powder shows low flowability (a good powder flowability is required to achieve constant thickness powder layers). The influence of SLM process parameters is widely described in the literature with reference to the density, surface topology, and dimensional accuracy of AlSi10Mg, microstructure or mechanical properties obtained [18,19]. Results of research conducted by Kempen et al [16] show that AlSi10Mg parts created with SLM process have good mechanical properties, comparable or even better than parts manufactured with casting processes.…”