Influence of Heat Treatment on Ultra-Precision Finishing Performance of Laser Powder Bed-Fused AlSi10Mg Alloys
摘要
Additive manufacturing (AM) of metals has received remarkable attention in recent times due to the ever-increasing demand for customization in industries. The technology is widely adopted for batch production and produces parts by ensuring minimal wastage of material. However, the undesirable level of surface integrity associated with the metal AM components does not qualify the standards as per industrial requirements. Ultra-precision finishing (UPF) process using diamond tool can impart nanofinish over LPBF components, thereby favoring industrial acceptance. Nevertheless, the final surface finish achieved by UPF is sensitive to the characteristic microstructure of laser powder bed-fused (LPBF) components. AlSi10Mg is a metal AM alloy widely used in the fabrication of lightweight mirrors and visible/near-infrared optical systems. The UPF performance in processing LPBF AlSi10Mg is strongly dependent on the presence of ductile (Al) and brittle (Si) constituents in the material. Thus, the present study investigates the influence of solution treatment + aging on the finishing characteristics and surface attributes of LPBF AlSi10Mg components. The tool feed marks featured over machined surface of LPBF samples, whereas material displacement/dislodgement occurs in case of heat-treated samples. The study also showed that heat treatment leads to increase in surface roughness (Ra = ~ 25.4 nm) relative to non-heat-treated samples (Ra = 13.7 nm) due to the microstructural variations, however, with drop in material hardness. In addition, heat treatment results in uniform dispersion of Si particles/precipitates over the Al matrix. Consequently, continuous and longer chip formation with smaller serrations are observed during UPF indicating enhanced machinability of AlSi10Mg samples. In summary, the present study confirms that solution heat treatment has a crucial role in controlling the machinability and surface integrity of LPBF AlSi10Mg samples.