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<p>Selective laser melting (SLM) is a widely used laser powder bed fusion (LPBF) technique that builds components layer by layer using localized melting. SLM-based additive manufacturing (AM) has been widely used in the automotive and aerospace sectors to produce lightweight parts. The quality and performance of LPBF-AM products are significantly influenced by build orientation and process parameters. The primary objective of this study is to enhance the mechanical properties of SLM-produced components by optimizing process parameters and comparing them with conventionally cast Al6061 alloy. The work focuses on both static and dynamic mechanical properties of the AlSi10Mg alloy fabricated by LPBF, including tensile strength, hardness, microstructural characteristics, rotational bending fatigue performance, and wear behavior. Before LPBF printing, additive manufacturing (AM) simulation was performed to evaluate part performance within the build chamber. The simulation predicted a chamber temperature distribution of 492.85&#xa0;°C during printing and a part displacement of 0.04328&#xa0;mm. Experimental studies were carried out under two conditions: as-built (room temperature) and post-heat treated (200&#xa0;°C for 2&#xa0;h). The best results achieved were as follows: density of 2.66&#xa0;g/cm³ (99.6%), yield strength (YS) of 121&#xa0;MPa, ultimate tensile strength (UTS) of 342&#xa0;MPa, hardness of 129 ± 5 HV, and elongation of 10.33%. Fatigue performance thermally treated conditions, a maximum fatigue life of 2.16 × 10⁴ cycles was obtained at 116.11&#xa0;MPa. Wear characterization at a sliding speed of 200&#xa0;rpm and a load of 60&#xa0;N, the lowest wear rate (1.39 × 10⁻⁸ mm²/N) and wear coefficient (0.01&#xa0;mm²/N) were recorded. Both parameters increased with higher sliding speeds. The results demonstrate that LPBF-fabricated AlSi10Mg specimens exhibit superior mechanical properties in annealed conditions compared to both as-built conditions and conventionally cast Al6061 alloy. These improvements are attributed to the uniform distribution of the Si phase and the fine microstructure developed in LPBF parts. The optimal process parameters laser power of 225&#xa0;W, scan speed of 500&#xa0;mm/s, hatch distance of 100&#xa0;μm, and layer thickness of 30&#xa0;μm correspond to a laser energy density of 150&#xa0;J/mm³.</p>

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Mechanical characterization of heat-treated AlSi10Mg alloy fabricated using laser powder bed fusion additive manufacturing

  • 期刊论文

  • 发表日期：

    2025年11月13日

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  • Mudda Nirish,
  • Pentamaraju Madhavi,
  • Rega Rajendra

摘要

Selective laser melting (SLM) is a widely used laser powder bed fusion (LPBF) technique that builds components layer by layer using localized melting. SLM-based additive manufacturing (AM) has been widely used in the automotive and aerospace sectors to produce lightweight parts. The quality and performance of LPBF-AM products are significantly influenced by build orientation and process parameters. The primary objective of this study is to enhance the mechanical properties of SLM-produced components by optimizing process parameters and comparing them with conventionally cast Al6061 alloy. The work focuses on both static and dynamic mechanical properties of the AlSi10Mg alloy fabricated by LPBF, including tensile strength, hardness, microstructural characteristics, rotational bending fatigue performance, and wear behavior. Before LPBF printing, additive manufacturing (AM) simulation was performed to evaluate part performance within the build chamber. The simulation predicted a chamber temperature distribution of 492.85 °C during printing and a part displacement of 0.04328 mm. Experimental studies were carried out under two conditions: as-built (room temperature) and post-heat treated (200 °C for 2 h). The best results achieved were as follows: density of 2.66 g/cm³ (99.6%), yield strength (YS) of 121 MPa, ultimate tensile strength (UTS) of 342 MPa, hardness of 129 ± 5 HV, and elongation of 10.33%. Fatigue performance thermally treated conditions, a maximum fatigue life of 2.16 × 10⁴ cycles was obtained at 116.11 MPa. Wear characterization at a sliding speed of 200 rpm and a load of 60 N, the lowest wear rate (1.39 × 10⁻⁸ mm²/N) and wear coefficient (0.01 mm²/N) were recorded. Both parameters increased with higher sliding speeds. The results demonstrate that LPBF-fabricated AlSi10Mg specimens exhibit superior mechanical properties in annealed conditions compared to both as-built conditions and conventionally cast Al6061 alloy. These improvements are attributed to the uniform distribution of the Si phase and the fine microstructure developed in LPBF parts. The optimal process parameters laser power of 225 W, scan speed of 500 mm/s, hatch distance of 100 μm, and layer thickness of 30 μm correspond to a laser energy density of 150 J/mm³.