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<p>Arched overhanging structures are frequently used in selective laser melting (SLM) of complex parts, representing a standard unsupported structure. Research on unsupported structures in metal additive manufacturing is still in its early stages, facing numerous challenges. This study used SLM to fabricate arched overhanging structures with Al–Mg–Sc–Zr alloy powder, focusing on the impact of transition fillet radius (R) on surface quality. Results show that increasing R reduces the line roughness (Ra) and its measurement error (<i>Ir</i>​). The minimum maximum surface height difference (Sz) was observed at R = 8&#xa0;mm.The fillet region’s surface morphology consists of powder adhesion, block-like protrusions, agglomeration, and bonding. powder adhesion decrease as R increases, with the largest smooth areas at R = 8&#xa0;mm. Cross-sectional observations revealed a smooth section and an area with adhered particles. The angle θ between the boundary of these two regions and the horizontal line increases with increasing R. A critical unsupported distance S exists at the corresponding angle θ, approximately 30.62&#xa0;μm, close to the average powder particle size. When S is less than the critical value, the surface is smooth; otherwise, powder adhesion and aggregation occur, affecting surface quality.</p> Graphical abstract <p></p>

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The effect of transition fillets on the surface quality of arched overhanging structures created by SLM

  • 期刊论文

  • 发表日期：

    2025年11月24日

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  • Boyang li,
  • Qiang Liu,
  • Yi Chen,
  • Wanqian Hu,
  • Yong-de Huang

摘要

Arched overhanging structures are frequently used in selective laser melting (SLM) of complex parts, representing a standard unsupported structure. Research on unsupported structures in metal additive manufacturing is still in its early stages, facing numerous challenges. This study used SLM to fabricate arched overhanging structures with Al–Mg–Sc–Zr alloy powder, focusing on the impact of transition fillet radius (R) on surface quality. Results show that increasing R reduces the line roughness (Ra) and its measurement error (Ir​). The minimum maximum surface height difference (Sz) was observed at R = 8 mm.The fillet region’s surface morphology consists of powder adhesion, block-like protrusions, agglomeration, and bonding. powder adhesion decrease as R increases, with the largest smooth areas at R = 8 mm. Cross-sectional observations revealed a smooth section and an area with adhered particles. The angle θ between the boundary of these two regions and the horizontal line increases with increasing R. A critical unsupported distance S exists at the corresponding angle θ, approximately 30.62 μm, close to the average powder particle size. When S is less than the critical value, the surface is smooth; otherwise, powder adhesion and aggregation occur, affecting surface quality.

Graphical abstract