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<p>As an essential technology in metal additive manufacturing (AM), laser powder bed fusion (LPBF) has garnered significant attention owing to its unique capability to fabricate complex structural components with high design freedom, near-perfect density and enhanced mechanical properties. Herein, the influences of processing parameters on the microstructure characteristics and mechanical properties of LPBF-built AlSi10Mg samples are experimentally investigated, and a finite element model with multi-track laser scanning is developed to explore the effect of non-equilibrium solidification on the formation of metallurgical defects and microstructure evolution during LPBF process. The experimental results demonstrate that the tensile properties of LPBF-built samples can be significantly enhanced by decreasing the porosity level, and the optimized processing parameters yield an ultimate tensile strength (UTS) of 448 ± 3 MPa and an elongation to failure of 8.3 ± 0.9%. Analysis of predicted melting pool morphologies indicates that the formation mechanism of the melting pool is conductive melting, and the lack-of-fusion defects can be eliminated through the optimization of the overlap ratio between adjacent melting pools. Simulation results confirm that the cooling rate serves as a reliable indicator of <i>α</i>-Al cell size in the microstructure of LPBF-built AlSi10Mg, and fine cellular structures with cell size of ~ 0.45μm are obtained when performing a high scanning speed of 1200&#xa0;mm/s. Notably, the correlation between the mechanical properties and the solidification cell size also indicates that the UTS and yield strength can be highly improved with the refinement of the <i>α</i>-Al cells, while the elongation to failure remains highly sensitive to the microstructural defects.</p>

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Investigations on the Correlation of Mechanical Properties and Microstructures with Thermal Behavior of AlSi10Mg Alloy during Laser Powder Bed Fusion

  • 期刊论文

  • 发表日期：

    2025年8月29日

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  • Jiangwei Liu,
  • Zedong Zhang,
  • Kangkang Zhao,
  • Yu Sun,
  • Hu Li

摘要

As an essential technology in metal additive manufacturing (AM), laser powder bed fusion (LPBF) has garnered significant attention owing to its unique capability to fabricate complex structural components with high design freedom, near-perfect density and enhanced mechanical properties. Herein, the influences of processing parameters on the microstructure characteristics and mechanical properties of LPBF-built AlSi10Mg samples are experimentally investigated, and a finite element model with multi-track laser scanning is developed to explore the effect of non-equilibrium solidification on the formation of metallurgical defects and microstructure evolution during LPBF process. The experimental results demonstrate that the tensile properties of LPBF-built samples can be significantly enhanced by decreasing the porosity level, and the optimized processing parameters yield an ultimate tensile strength (UTS) of 448 ± 3 MPa and an elongation to failure of 8.3 ± 0.9%. Analysis of predicted melting pool morphologies indicates that the formation mechanism of the melting pool is conductive melting, and the lack-of-fusion defects can be eliminated through the optimization of the overlap ratio between adjacent melting pools. Simulation results confirm that the cooling rate serves as a reliable indicator of α-Al cell size in the microstructure of LPBF-built AlSi10Mg, and fine cellular structures with cell size of ~ 0.45μm are obtained when performing a high scanning speed of 1200 mm/s. Notably, the correlation between the mechanical properties and the solidification cell size also indicates that the UTS and yield strength can be highly improved with the refinement of the α-Al cells, while the elongation to failure remains highly sensitive to the microstructural defects.