Laser Powder Bed Fusion Process Optimization of AlSi10Mg Alloy Using Selective Laser Melting: Dynamic Performance of Fatigue Behaviour, Microstructure, Hardness and Density

Abstract

The quality of a selective laser melting (SLM) component depends on build orientation and layer thickness, which are directly influenced by processing parameters. The present research of layer-by-layer additive simulation before starting the SLM process has several advantages, such as saving time, cost, and material. In this main investigation, the dynamic performance of fatigue strength, density, and hardness of AlSi10Mg alloy was produced by the SLM-AM according to the design of experiments. The L9 orthogonal array of the Taguchi method was created to perform the experimental development process. Finally, the obtained optimal process parameter with the highest values of fatigue strength, density, and hardness was found at a laser power of 225 Watts, a scan speed of 500 mm/s, and a hatching distance of 100 μm. The experimental density result was achieved with a high density value of 99.6% (2.66 g/cm3) and a defect-free component and hardness of 126±5 HV. The future scope of this study will use optimal process parameters to find out mechanical properties for as built and preheated conditions for aerospace applications.