The Effects of Selective Laser Melting Process Parameters on Relative Density of the AlSi10Mg Parts and Suitable Procedures of the Archimedes Method

Shigang Bai,Nataliya Perevoshchikova,Yu Sha,Xinhua Wu

doi:10.3390/app9030583

Shigang Bai, Nataliya Perevoshchikova + Show 2 more

Open Access

https://doi.org/10.3390/app9030583

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Abstract

In view of the importance of accurately measuring the relative density of a selective laser melted (SLMed) part for optimizing the selective laser melting (SLM) processing parameters, suitable procedures of the Archimedes method considering the surface-connected cavities were proposed by comparing the results using the Archimedes method with image analysis. The effects of the SLM processing parameters on the relative density of AlSi10Mg were investigated using the proposed procedures of the Archimedes methods and image analysis. Fourteen SLMed samples were produced by different SLM processing parameters according to Doehlert Matrix. The regression models correlating relative density and three SLM processing parameters (laser power, scan speed, and hatching distance) were built and the optimum parameter combination to get a high relative density was obtained. By plotting the response surfaces and contours of the regression models, it was found that the relative densities are both higher at the combination of the higher scan speed, higher power, and lower hatching distance and at the combination of a lower scan speed, a moderate laser power, and a optional hatching distance. It was also found that the parameter of hatching distance is the crucial parameter to get a high relative density and to get high mechanical property.

Highlights

Selective laser melting (SLM) is of huge interest for the production of complex shaped metal parts for the gas turbine industry and some nuclear applications [1,2]
The selective laser melting (SLM) process uses a laser, which scans over and selectively melts metal powder in a powder bed to build 3D components layer by layer according to the design in a computer-aided design (CAD) file [3]
4, method 2-2, or method 3-2 (Archimedes method considering the open cavities effect) should be used for the AlSi10Mg selective laser melted (SLMed) samples, especially for the sample with a density lower than 99%, which is measured using the Archimedes method without considering the open cavities effect according to Table 2

Summary

Introduction

Selective laser melting (SLM) is of huge interest for the production of complex shaped metal parts for the gas turbine industry and some nuclear applications [1,2]. The SLM process uses a laser, which scans over and selectively melts metal powder in a powder bed to build 3D components layer by layer according to the design in a computer-aided design (CAD) file [3]. The AlSi10Mg alloy is highly demanded for many applications in aerospace, automotive industry, and heat exchanger products [3], due to its lightweight, low thermal expansion and recycling costs, and high mechanical properties [4]. AlSi10Mg components have a wide range of mechanical properties, an extremely fine microstructure, and a high hardness [8,9]

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