Abstract
Selective laser melting (SLM) is widely gaining popularity as an alternative manufacturing technique for complex and customized parts. SLM is a near net shape process with minimal post processing machining required dependent upon final application. The fact that SLM produces little waste and enables more optimal designs also raises opportunities for environmental advantages. The use of aluminium (Al) alloys in SLM is still quite limited due to difficulties in processing that result in parts with high degrees of porosity. However, Al alloys are favoured in many high-end applications for their exceptional strength and stiffness to weight ratio meaning that they are extensively used in the automotive and aerospace industries. This study investigates the windows of parameters required to produce high density parts from AlSi10Mg alloy using selective laser melting. A compromise between the different parameters and scan strategies was achieved and used to produce parts achieving a density of 99.8%.
Highlights
There is a current need to manufacture geometrically complex structures that are light-weight
Additive manufacturing (AM) of metallic materials from metallic powder using a laser heat source is often referred to as selective laser melting (SLM) [1,2,3,4]
This paper aims to understand the mechanisms of pore formation as an approach towards eliminating them
Summary
There is a current need to manufacture geometrically complex structures that are light-weight. SLM has outstanding ecological indicators since it saves resources as the waste has the potential of approaching zero Another indicator is eco-design optimization since the technique allows complex parts to be created monolithically, so it allows light weight structuring with a typically. SLM can produce complex parts – that would require a series of manufacturing processes if made by conventional techniques consuming excess material (i.e. waste), time and energy – in one go. The major build parameters involved in the process of selective laser melting are scanning speed, hatch spacing, laser power and layer thickness. The aim of this paper is to use design of the scanning strategy to enhance the relative density of parts being processed, i.e. minimize the porosity. The importance of manipulating the scanning strategy is that it can be used to amend the defects that are induced during the first scan of the current or preceding layer
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