Mechanical Properties, Microstructural and Surface Topography Evaluation of AlSi10Mg Alloy Produced by DMLS Process

Abstract

In this paper, direct metal laser sintering process was used to produce AlSi10Mg components by employing different parametric combinations. Laser intensity, scan speed, and hatch distance were regarded as the autonomous parameters. A laser energy density (led) function expressed these three parameters. Fabricated component’s density was evaluated by the Archimedes principle. Measured densities were demonstrated as relative density (rd) by indicating it as percentage of the actual density of the alloy (2.67 gm/cm³). In our study, the led–rd–structure relationship is discussed. The highest led of 93.43 J/mm³ yielded the least rd of 95.88%. Its microstructure showed numerous irregularly shaped pores; its surface topography also revealed a large amount of balling and satellite formation, whereas for the sample with the maximum rd value of 99.63%, which was fabricated by employing a led of 61.11 J/mm³, it showed very few pores and almost negligible balling formation. The above analysis revealed that surface topography also had an impactful role in determining the density of the component. This study also showed an interrelation between relative density and tensile strength of the alloy; the component with the best relative density showed a higher ultimate tensile strength value than the component with the least relative density value. A superior tensile strength property of the dog bone sample with the highest relative density was found when it was compared with the tensile strength properties of the A360 die-cast material.