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<p>The Al-Mg-Si alloy is a well-known commercial aluminum alloy, commonly utilized in the aerospace and automotive industries due to its excellent mechanical properties and lightweight characteristics. However, its use in laser powder bed fusion (LPBF) additive manufacturing faces limitations primarily due to the formation of internal porosity defects that occur during the rapid solidification process. These porosity issues can significantly affect the material’s mechanical integrity and overall performance. This study focuses on the Al-Mg-Si alloy. It investigates the internal defects, microstructure, and mechanical properties of LPBF Al-Mg-Si alloy produced under different laser power and scanning speeds in a high scanning speed range. The findings indicate that with the laser power configured at 450 W and the scanning speed set to 1250&#xa0;mm/s, the LPBF Al-Mg-Si alloy achieves a relative density of 99.87%. No low-sphericity microcracks are observed. The study also notes the presence of nanoscale Si-Fe-Mg enriched precipitates in the final product. Tensile tests reveal that the samples have an elongation exceeding 20% and a tensile strength of 213&#xa0;MPa. This indicates that the produced alloy exhibits good mechanical properties. Additionally, the samples show weak anisotropy. This work demonstrates the feasibility of improving the forming quality and mechanical properties of LPBF Al-Mg-Si alloy by adjusting processing parameters. It provides valuable insights for the alloy’s application in industrial settings.</p>

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Feasibility Study on High Processing Efficiency of Commercial Al-Mg-Si Aluminum Alloy for Laser Powder Bed Melting Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2025年10月23日

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  • Ming Li,
  • Yanbin Sun,
  • Guojian Luo

摘要

The Al-Mg-Si alloy is a well-known commercial aluminum alloy, commonly utilized in the aerospace and automotive industries due to its excellent mechanical properties and lightweight characteristics. However, its use in laser powder bed fusion (LPBF) additive manufacturing faces limitations primarily due to the formation of internal porosity defects that occur during the rapid solidification process. These porosity issues can significantly affect the material’s mechanical integrity and overall performance. This study focuses on the Al-Mg-Si alloy. It investigates the internal defects, microstructure, and mechanical properties of LPBF Al-Mg-Si alloy produced under different laser power and scanning speeds in a high scanning speed range. The findings indicate that with the laser power configured at 450 W and the scanning speed set to 1250 mm/s, the LPBF Al-Mg-Si alloy achieves a relative density of 99.87%. No low-sphericity microcracks are observed. The study also notes the presence of nanoscale Si-Fe-Mg enriched precipitates in the final product. Tensile tests reveal that the samples have an elongation exceeding 20% and a tensile strength of 213 MPa. This indicates that the produced alloy exhibits good mechanical properties. Additionally, the samples show weak anisotropy. This work demonstrates the feasibility of improving the forming quality and mechanical properties of LPBF Al-Mg-Si alloy by adjusting processing parameters. It provides valuable insights for the alloy’s application in industrial settings.