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<p>One of the many challenges toward widespread use of metal additive manufacturing is limited build volume. Laser welding was used to join additively manufactured (AM) AlSi10Mg aluminum alloy sheets. Several combinations of welding parameters, i.e., welding speed, laser power, and shielding gas flow rate, were used in order to select a combination that produces minimum weld porosity and highest mechanical joint strength. Characterization technique, viz., nano-CT along with <i>X</i>-ray radiography, was used in this study to analyze the porosity generated during welding. Optical microscopy and SEM microstructure study showed that the welding speed may refine the grains and encourage the even dispersion of Si particles and metastable precursors to Mg<sub>2</sub>Si particles in the weld fusion zone, which would increase the weld zone’s microhardness. With power set at 2700&#xa0;W, welding speed of 24&#xa0;mm/s and the flow rate of shielding (argon) gas at 15&#xa0;lpm, the weld porosity could be minimized and tensile strength and elongation were also in consonance with the porosity.</p>

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Effect of Weld Parameters on Porosity Reduction in Laser Beam-Welded AlSi10Mg Parts Made by Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2026年1月2日

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  • Ajay Kumar Vishwakarma,
  • Makarand Pawar,
  • Dibyendu Debnath,
  • Vijay D. Hiwarkar,
  • Himanshu Shekhar,
  • Praveen Kumar B.,
  • Bikash Ghose

摘要

One of the many challenges toward widespread use of metal additive manufacturing is limited build volume. Laser welding was used to join additively manufactured (AM) AlSi10Mg aluminum alloy sheets. Several combinations of welding parameters, i.e., welding speed, laser power, and shielding gas flow rate, were used in order to select a combination that produces minimum weld porosity and highest mechanical joint strength. Characterization technique, viz., nano-CT along with X-ray radiography, was used in this study to analyze the porosity generated during welding. Optical microscopy and SEM microstructure study showed that the welding speed may refine the grains and encourage the even dispersion of Si particles and metastable precursors to Mg2Si particles in the weld fusion zone, which would increase the weld zone’s microhardness. With power set at 2700 W, welding speed of 24 mm/s and the flow rate of shielding (argon) gas at 15 lpm, the weld porosity could be minimized and tensile strength and elongation were also in consonance with the porosity.