Skip to main content

Advertisement

SpringerLink
Log in

Geometric characteristics of AlSi10Mg ultrathin walls fabricated by selective laser melting with energy density and related process parameters

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In applications requiring large specific surface area, ultrathin walls fabricated by selective laser melting (SLM) have attracted wide attention. Understanding that the geometric characteristics of ultrathin walls are affected by process parameters is an important topic. To investigate the influence of SLM process parameters on geometric morphology, interlayer banding characteristics, and defects of the AlSi10Mg ultrathin walls, based on the normalized processing map, the multi-layers and single-track SLM tests under different energy density and interlayer cooling conditions were implemented. The ultrathin walls with the width between 100 μm and 450 μm were successfully fabricated in the range of single-track energy density between 5 and 30, and their geometric morphology and interlayer banding characteristics are not significantly affected by the interlayer cooling time. Except that the height of thin walls does not change significantly with the process parameters, the width, penetration depth, and cross-sectional area of molten pool all have a power function decreasing relationship with the scanning speed, and all have a linearly increasing relationship with the laser power and single-track energy density, respectively. The macroscopic banding distance decreases linearly with the increase of laser power and single-track energy density and decreases exponentially with the decrease of scanning speed. When the single-track energy density is about 5 and 25, it is easier to obtain a more uniform banding distance close to the standard preset layer thickness under high power (≥ 300 W) with lower scanning speed (≤ 0.589746 m/s). The process parameter combination of high laser power (≥ 300 W) and low energy density (E* = 5) contributes to obtaining ultrathin-walled structures with the narrowest width of about 100 μm. Within the range of single-track energy density of 10 to 20, the use of appropriate laser power and scanning speed can be expected to avoid “necking,” “keyhole pore,” and “cracking” defects. This work provides guidance for choosing reasonable SLM process parameters when fabricating ultrathin walls in practical engineering applications.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

Similar content being viewed by others

Data Availability

Not applicable.

Code availability

Not applicable.

References

  1. Herzog D, Seyda V, Wycisk E, Emmelmann C (2016) Additive manufacturing of metals. Acta Mater 117:371–392

    Article  Google Scholar 

  2. Bharath C, Shamanth V, Hemanth K (2020) Studies on mechanical behaviour of AlSi10Mg alloy produced by selective laser melting and A360 alloy by die casting. Mater Today Proc:S2214785320376732

  3. Kempen K, Thijs L, Van Humbeeck J, Kruth JP (2015) Processing AlSi10Mg by selective laser melting: parameter optimization and material characterization. Mater Sci Technol 31:917–923

    Article  Google Scholar 

  4. Kong D, Ni X, Dong C, Zhang L, Cheng M, Cheng X, Li X (2019) Anisotropy in the microstructure and mechanical property for the bulk and porous 316L stainless steel fabricated via selective laser melting. Mater Lett 235:1–5

    Article  Google Scholar 

  5. Ataee A, Li Y, Brandt M, Wen C (2018) Ultrahigh-strength titanium gyroid scaffolds manufactured by selective laser melting (SLM) for bone implant applications. Acta Mater 158:354–368

    Article  Google Scholar 

  6. Ho JY, Leong KC, Wong TN (2020) Additively-manufactured metallic porous lattice heat exchangers for air-side heat transfer enhancement. Int J Heat Mass Transf 150:119262

    Article  Google Scholar 

  7. Leary M, Mazur M, Elambasseril J, McMillan M, Chirent T, Sun Y, Qian M, Easton M, Brandt M (2016) Selective laser melting (SLM) of AlSi12Mg lattice structures. Mater Des 98:344–357

    Article  Google Scholar 

  8. Calignano F, Cattano G, Manfredi D (2018) Manufacturing of thin wall structures in AlSi10Mg alloy by laser powder bed fusion through process parameters. J Mater Process Technol 255:773–783

    Article  Google Scholar 

  9. Thijs L, Kempen K, Kruth JP, Van Humbeeck J (2013) Fine-structured aluminium products with controllable texture by selective laser melting of pre-alloyed AlSi10Mg powder. Acta Mater 61:1809–1819

    Article  Google Scholar 

  10. Anwar AB, Pham QC (2017) Selective laser melting of AlSi10Mg: Effects of scan direction, part placement and inert gas flow velocity on tensile strength. J Mater Process Technol 240:388–396

    Article  Google Scholar 

  11. Trevisan F, Calignano F, Lorusso M, Pakkanen J, Aversa A, Ambrosio E, Lombardi M, Fino P, Manfredi D (2017) On the selective laser melting (SLM) of the AlSi10Mg alloy: process, microstructure, and mechanical properties. Materials 10:76

    Article  Google Scholar 

  12. Read N, Wang W, Essa K, Attallah MM (2015) Selective laser melting of AlSi10Mg alloy: process optimisation and mechanical properties development. Mater Des 1980-2015 65:417–424

    Google Scholar 

  13. Zhang S, Wei Q, Cheng L, Li S, Shi Y (2014) Effects of scan line spacing on pore characteristics and mechanical properties of porous Ti6Al4V implants fabricated by selective laser melting. Mater Des 63:185–193

    Article  Google Scholar 

  14. Yadroitsev I, Shishkovsky I, Bertrand P, Smurov I (2009) Manufacturing of fine-structured 3D porous filter elements by selective laser melting. Appl Surf Sci 255:5523–5527

    Article  Google Scholar 

  15. Su X, Yang Y, Xiao D, Luo Z (2013) An investigation into direct fabrication of fine-structured components by selective laser melting. Int J Adv Manuf Technol 64:1231–1238

    Article  Google Scholar 

  16. Abele E, Stoffregen HA, Kniepkamp M, Lang S, Hampe M (2015) Selective laser melting for manufacturing of thin-walled porous elements. J Mater Process Technol 215:114–122

    Article  Google Scholar 

  17. Jiang J, Ma Y (2020) Path planning strategies to optimize accuracy, quality, build time and material use in additive manufacturing: a review. Micromachines 11:633

    Article  Google Scholar 

  18. Kim DK, Hwang JH, Kim EY, Heo YU, Woo W, Choi SH (2017) Evaluation of the stress-strain relationship of constituent phases in AlSi10Mg alloy produced by selective laser melting using crystal plasticity FEM. J Alloys Compd 714:687–697

    Article  Google Scholar 

  19. Wang D, Wu S, Bai Y, Lin H, Yang Y, Song C (2017) Characteristics of typical geometrical features shaped by selective laser melting. J Laser Appl 29:022007

    Article  Google Scholar 

  20. Yadroitsev I, Smurov I (2010) Selective laser melting technology: from the single laser melted track stability to 3D parts of complex shape. Phys Procedia 5:551–560

    Article  Google Scholar 

  21. Thijs L, Verhaeghe F, Craeghs T, Humbeeck JV, Kruth JP (2010) A study of the microstructural evolution during selective laser melting of Ti–6Al–4V. Acta Mater 58:3303–3312

    Article  Google Scholar 

  22. Yadroitsev I, Krakhmalev P, Yadroitsava I, Johansson S, Smurov I (2013) Energy input effect on morphology and microstructure of selective laser melting single track from metallic powder. J Mater Process Technol 213:606–613

    Article  Google Scholar 

  23. Thomas M, Baxter GJ, Todd I (2016) Normalised model-based processing diagrams for additive layer manufacture of engineering alloys. Acta Mater 108:26–35

    Article  Google Scholar 

  24. Ion JC, Shercliff HR, Ashby MF (1992) Diagrams for laser materials processing. Acta Metall Mater 40:1539–1551

    Article  Google Scholar 

  25. Aboulkhair NT, Everitt NM, Ashcroft I, Tuck C (2014) Reducing porosity in AlSi10Mg parts processed by selective laser melting. Addit Manuf 1–4:77–86

    Google Scholar 

  26. Kempen K, Thijs L, Van Humbeeck J, Kruth JP (2012) Mechanical properties of AlSi10Mg produced by selective laser melting. Phys Procedia 39:439–446

    Article  Google Scholar 

  27. Li W, Li S, Liu J, Zhang A, Zhou Y, Wei Q, Yan C, Shi Y (2016) Effect of heat treatment on AlSi10Mg alloy fabricated by selective laser melting: microstructure evolution, mechanical properties and fracture mechanism. Mater Sci Eng A 663:116–125

    Article  Google Scholar 

  28. Biffi CA, Fiocchi J, Bassani P, Paolino DS, Tridello A, Chiandussi G, Rossetto M, Tuissi A (2017) Microstructure and preliminary fatigue analysis on AlSi10Mg samples manufactured by SLM. Procedia Struct Integr 7:50–57

    Article  Google Scholar 

  29. Yu T, Hyer H, Sohn Y, Bai Y, Wu D (2019) Structure-property relationship in high strength and lightweight AlSi10Mg microlattices fabricated by selective laser melting. Mater Des 182:108062

    Article  Google Scholar 

  30. Brandl E, Heckenberger U, Holzinger V, Buchbinder D (2012) Additive manufactured AlSi10Mg samples using selective laser melting (SLM): microstructure, high cycle fatigue, and fracture behavior. Mater Des 34:159–169

    Article  Google Scholar 

  31. Uzan NE, Shneck R, Yeheskel O, Frage N (2017) Fatigue of AlSi10Mg specimens fabricated by additive manufacturing selective laser melting (AM-SLM). Mater Sci Eng A 704:229–237

    Article  Google Scholar 

  32. Leary M, Maconachie T, Sarker A, Faruque O, Brandt M (2019) Mechanical and thermal characterisation of AlSi10Mg SLM block support structures. Mater Des 183:108138

    Article  Google Scholar 

  33. Silbernagel C, Ashcroft I, Dickens P, Galea M (2018) Electrical resistivity of additively manufactured AlSi10Mg for use in electric motors. Addit Manuf 21:395–403

    Google Scholar 

  34. Maamoun AH, Elbestawi M, Dosbaeva GK, Veldhuis SC (2018) Thermal post-processing of AlSi10Mg parts produced by selective laser melting using recycled powder. Addit Manuf 21:234–247

    Google Scholar 

  35. Kempen K, Thijs L, Yasa E, Badrossamay M, Verheecke W, Kruth JP (2011) Process optimization and microstructural analysis for selective laser melting of AlSi10Mg. Proc. Solid Free. Fabr. Symp. Texas, USA, In

    Google Scholar 

  36. Gusarov AV, Yadroitsev I, Bertrand P, Smurov I (2009) Model of radiation and heat transfer in laser-powder interaction zone at selective laser melting. J Heat Transf 131:70–79

    Article  Google Scholar 

Download references

Funding

This work was supported by China Postdoctoral Science Foundation (No. 2020M673587XB and No. 2020TQ0133), Yunnan Postdoctoral Research Found Project, Kunming University of Science and Technology Postdoctoral Academic Activities Foundation (No. 1323/109820190026), and Kunming University of Science and Technology Startup Research Grant for Distinguished Scholar (No. KKKP201751008).

Author information

Authors and Affiliations

  1. Faculty of Materials Science and Engineering, Kunming University of Science and Technology, Kunming, 650093, People’s Republic of China

    Xin Lu, Mengnie Victor Li & Hongbin Yang

Authors
  1. Xin Lu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Mengnie Victor Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Hongbin Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Xin Lu or Mengnie Victor Li.

Ethics declarations

Conflict of interest

The authors declare no competing interests.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Supplementary Information

ESM 1

(PDF 4.58 mb)

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Lu, X., Li, M.V. & Yang, H. Geometric characteristics of AlSi10Mg ultrathin walls fabricated by selective laser melting with energy density and related process parameters. Int J Adv Manuf Technol 115, 3773–3790 (2021). https://doi.org/10.1007/s00170-021-07414-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-07414-7

Keywords

Search

Navigation