In order to understand the microstructural characteristics of cellular (porous) AlSi10Mg alloy fabricated via selective laser melting (SLM), we designed SLM-fabricated AlSi10Mg alloy samples with various box-shaped structures containing interior X-shaped shelves as a representative model of porous aluminum. All fabricated samples exhibited characteristic microstructural morphologies comprising melt pools with columnar α-Al phases surrounded by fine eutectic Si particles. Several columnar α-Al phases exhibited 〈001〉 orientations along the elongation direction, resulting in a {001} texture. In the shelf wall regions of fabricated samples, the elongation direction of the columnar α-Al phases varied depending on the incline angle between the inclined wall plane and the laser irradiation direction (θ), reducing the formation of {001} texture in samples with high incline angles. In the regions wherein the X-shaped shelves intersect, the microstructure varied in different sections: the α-Al phases observed in the lower portion appeared coarser and more equiaxed compared with those in the upper portion. The microstructural difference was more significant in samples with higher incline angles, which contributes to the observed variations in hardness values. Based on the results obtained, we discuss the dominant factor leading to the observed inhomogeneity of the microstructure of cellular AlSi10Mg alloy fabricated via SLM.
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