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Spatter formation during laser beam melting of AlSi10Mg and effects on powder quality
摘要： Cost and resource efficiency of Laser Beam Melting (LBM) highly depend on powder recycling procedures. Non-solidified powder can be sieved and reused in subsequent build cycles. However, due to quality concerns, powder recycling is not commonly practiced. One effect, which can impair the powder quality, lies in the formation and insertion of spatter particles during the melting process. In this paper, spatter particles emerging during LBM of AlSi10Mg are characterized regarding geometric (size, morphology), chemical (alloy composition, oxygen content, oxide layer thickness) properties as well as mass. Spatter particles are collected during the process using two isolation methods. Three types of spatter particles can be differentiated by their formation mechanism. It is found that spatter particles can differ significantly in oxide layer thickness and particle size. A significant share of spatter particles can be segregated by sieving. However, a certain fraction of the spatter particles will be included in the recycled powder.
关键词： Laser beam melting,AlSi10Mg,Powder recycling,Powder quality,Powder bed fusion,Powder reuse,Additive manufacturing,Reusability,Oxidation,Spatter
更新于2025-09-12 10:27:22
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Machining induced residual stresses in AlSi10Mg component produced by Laser Powder Bed Fusion (L-PBF)
摘要： The adoption of metal powder-based laser process (L-PBF) for industrial applications continues to widen, due to an increasing knowledge on additive processes and the availability of new systems for industrial production. The use of L-PBF processes requires a deeper investigation and comparison on mechanical properties of conventional and additive parts. For instance, metal parts produced by L-PBF could require additional machining operations, which alter the stress state of additive components. In this work, the effect of machining operations on the residual stress state of an AlSi10Mg component produced by L-PBF is investigated by means of the semi destructive hole-drilling method.
关键词： AlSi10Mg,Machining,Hole-drilling method,Residual stresses,Laser Powder Bed Fusion
更新于2025-09-12 10:27:22
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Laser welding of AlSi10Mg aluminium-based alloy produced by Selective Laser Melting (SLM)
摘要： Additive manufacturing can produce very complex and highly integrated parts that cannot be manufactured by traditional methods. In many of its applications, the AM-manufactured part may be a very small part of the whole, and therefore it has become increasingly important to find suitable attachment methods for printed parts. The aim of this study was to find out the laser weldability of the printed AlSi10Mg material without filler material. The laser used in these welding experiments was Yb:YAG disk laser. The laser wavelength was 1030 nm and the maximum output power on the workpiece surface was 4 kW. AlSi10Mg is a widely used material in parts that are produced utilizing the SLM technique. The material has very good corrosion resistance properties, good electrical conductivity and excellent thermal conductivity. AlSi10Mg has proven to be much easier to print than steel materials, so it is a popular material also in prototype production. Based on welding tests, laser welding without filler material is suitable for AlSi10Mg material and the static strength of the weld is reasonably good compared to the base material. However, AlSi10Mg can be found to be challenging due to its composition.
关键词： Selective Laser Melting (SLM),AlSi10Mg,Yb:YAG disk laser,Laser welding,Additive Manufacturing (AM)
更新于2025-09-12 10:27:22
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Disk Laser Assisted Surface Heat Treatments Of AlSi10Mg Parts Produced By Selective Laser Melting (SLM)
摘要： Metal parts produced with the Selective Laser Melting (SLM) method have a great variety of uses today and because of this the requirements on the surface quality differ between applications. The surface treatments of the printed metal pieces, like other finishing phases, are often still manually worked on and thus are very time-consuming processes. This study focuses on the SLM printed AlSi10Mg aluminium specimen’s surface laser heat treatment with disk laser equipment (wavelength of 1030nm). The goal of this study was to achieve the desired effect on the aluminium’s surface quality with robotized laser heat treatment equipment. This was to show that the used finishing treatment method could be automated or robotized. The study showed that with the correct laser parameters, it is possible to generate desired effects and features on to the AlSi10Mg aluminium piece’s surface with a robotized process.
关键词： Selective Laser Melting (SLM),laser forming,AlSi10Mg,Additive Manufacturing (AM)
更新于2025-09-12 10:27:22
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Overmelting and closing of thin horizontal channels in AlSi10Mg samples obtained by selective laser melting
摘要： This paper presents the results of numerical simulations and experimental tests on AlSi10Mg samples, having thin cylindrical channels built in the horizontal direction, using selective laser melting technology. The thermal state of the samples with channels of varying diameters is investigated by employing a simplified part-scale transient model that takes into consideration the overmelting effects through the change of the materials properties related with phase transition effects in the melted area of the sample. Comparison of simulation results and computing tomography of experimental samples reveal that the final cross section geometry of thin channels can be predicted and evaluated by the proposed model. Namely, it is found that the unsupported down-skin area of the channels is processed with formation of protrusions due to presence of the low conductive powder bed under the melted metal layer. This powder area overheated during laser action and melted together with desirable solid region of the model. Overmelting effects lead to the total closing of the channels with diameter less than 200 μm, partial closing of the channels of diameters 0.2-1 mm, and distortion of the cross section of larger channels. Possible approaches of adjusting the geometry of a channel are studied, considering the teardrop and enlarged shapes of the cross sections, which could help obtain a predefined cylindrical shape of the channels.
关键词： Thermal analysis,AlSi10Mg,Selective laser melting,Overmelting,Horizontal channels
更新于2025-09-12 10:27:22
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Effect of Surface and Subsurface Defects on Fatigue Behavior of AlSi10Mg Alloy Processed by Laser Powder Bed Fusion (L-PBF)
摘要： The fatigue behaviour of an AlSi10Mg alloy processed by laser powder bed fusion (L-PBF) and subjected to different surface finishing processes was investigated paying special attention to the residual defects on the surface and the dominant fatigue failure mechanisms. Roughness measurements and qualitative surface morphology analysis showed smooth surfaces in the case of vibro-finishing and machining followed by polishing. The fatigue performance did not reveal to be directly related to surface roughness, but residual intrusions left on the finished surfaces. Post-mortem analysis showed single- or multiple-crack nucleation from pores opened on the surface, un-melted powders, or spatters considered as typical L-PBF defects. A fatigue limit of 195 MPa for machined and polished samples was obtained by substantial removal of surface and subsurface defects.
关键词： surface texture,laser powder bed fusion,AlSi10Mg alloy,surface finishing,fatigue strength
更新于2025-09-11 14:15:04
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Laser Weldability of AlSi10Mg Alloy Produced by Selective Laser Melting: Microstructure and Mechanical Behavior
摘要： Selective laser melting (SLM) allows 3D complex parts to be produced with integrated functionalities but does not permit to realize large dimension parts, as the building chamber volume of commercial SLM systems is limited. Therefore, the possibility of joining SLM-built parts by welding appears as extremely valuable. In this work, laser weldability of SLMed AlSi10Mg parts has been investigated. The cooling rates induced by the welding process are lower than the ones of SLM; therefore, typical eutectic silicon network of SLM-built parts appears broken in both the melted zone and part of the heat-affected zone, as con?rmed by calorimetric measurement. This microstructural evolution caused a local decrease of hardness from 132 HV to 73 HV and a reduction of ductility caused by porosity formation in the weld bead. Moreover, the thermal treatment, performed at 320°C, can limit the gap of tensile response among welded bead and base SLM material.
关键词： laser welding,selective laser melting,mechanical testing,microstructure,AlSi10Mg
更新于2025-09-11 14:15:04
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Performance analysis of tool electrode prepared through laser sintering process during electrical discharge machining of titanium
摘要： Nowadays, additive manufacturing (AM)-based rapid prototyping (RP) is used as a convenient route for making tool electrodes required in electrical discharge machining (EDM). AM enables direct fabrication of complex shaped EDM electrode in comparatively less time in contrast to subtractive machining processes. In this study, an EDM electrode is prepared directly by selective laser sintering (SLS) process using metal matrix composite of aluminium (Al), silicon (Si) and magnesium (Mg). To study the performance of the prepared RP tool electrode in electrical discharge machining, titanium is used as workpiece material and EDM-30 oil as dielectric medium during machining. The performance of the prepared tool electrode is compared with conventional copper and graphite tool electrodes. Experiments have been conducted changing EDM process parameters viz. open circuit voltage (V), peak current (Ip), duty cycle (τ) and pulse duration (Ton) along with three tool electrodes such as RP, graphite and copper tool electrodes. The performance measures considered during the experimental study are material removal rate (MRR), tool wear rate (TWR), average surface roughness (Ra), white layer thickness (WLT), surface crack density (SCD) and micro-hardness (MH) on white layer. SEM and EDX of the machined surface reveal that tool material is generally eroded and deposited on the machined surface with formation of metal carbides. However, tool erosion is more pronounced in case of RP tool electrode. XRD analysis reveals the formation of titanium carbides on the machined surface resulting in increase in the micro-hardness of white layer. Discharge current and tool type are found to be significant parameters influencing the performance measures considered in the study. The surface produced when machined with RP tool electrode exhibits superior surface characteristics while graphite tool electrode produces better MRR and TWR.
关键词： Selective laser sintering,Electrical discharge machining,AlSi10Mg,Titanium
更新于2025-09-11 14:15:04
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Study on magnetic abrasive finishing of AlSi10Mg alloy prepared by selective laser melting
摘要： Selective laser melting (SLM) technology is playing an increasingly important role in today’s manufacturing industry. However, the surface quality of SLM samples is relatively poor and cannot be directly applied to industrial production. Therefore, this paper focuses on the post-treatment process of SLM AlSi10Mg alloy. First, the rough machining is performed by a grinding process (GP), and then, the magnetic abrasive finishing (MAF) is used for finish machining. The experiment results show that the combination of GP and MAF can effectively reduce the surface roughness and improve the surface quality of SLM AlSi10Mg alloy. The GP reduced the surface roughness to drop from 7 μm (after SLM forming) to about 0.6 μm, and the rough surface with defects such as spheroids and pits evolved into the fine surface with scratches and pores. The MAF reduced the surface roughness to a minimum of 0.155 μm, which resulted in excellent surface morphology. The surface hardness after the GP was higher, and the MAF reduced the hardness of the GP surface.
关键词： Grinding process,Hardness,AlSi10Mg alloy,Selective laser melting,Surface roughness,Magnetic abrasive finishing
更新于2025-09-11 14:15:04
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Performance Consistency of AlSi10Mg Alloy Manufactured by Simulating Multi Laser Beam Selective Laser Melting (SLM): Microstructures and Mechanical Properties
摘要： Multi-laser beam selective laser melting (SLM) technology based on a powder bed has been used to manufacture AlSi10Mg samples. The AlSi10Mg alloy was used as research material to systematically study the performance consistency of both the laser overlap areas and the isolated areas of the multi-laser beam SLM manufactured parts. The microstructures and mechanical properties of all isolated and overlap processing areas were compared under optimized process parameters. It was discovered that there is a raised platform at the junction of the overlap areas and the isolated areas of the multi-laser SLM samples. The roughness is significantly reduced after two scans. However, the surface roughness of the samples is highest after four scans. As the number of laser scans increases, the relative density of the overlap areas of the samples improves, and there is no significant change in hardness. The tensile properties of the tensile samples are poor when the overlap area width is 0, 0.1, or 0.2 mm. When the widths of the overlap areas are equal to or greater than 0.3 mm, there is no significant difference in the tensile strength between the overlap and the isolated areas.
关键词： selective laser melting,AlSi10Mg,microstructure,multi-laser manufacturing,mechanical property
更新于2025-09-09 09:28:46