International Journal Of 3D Printing And Additive Manufacturing

This study aim of investigates the obtained process parameters required to improved fatigue strength with highest dense parts manufactured by selective laser melting (SLM) of AlSi10Mg alloy and thermal simulation also important role for conducted before printing process to observe the thermal gradient and displacement, other stress developed on specimen i.e., save time, cost and material. The specimens were manufactured by SLM for cyclic bending fatigue performance. The metallurgical pores, fractures, and isolated areas with overlap of thermal gradient created at high power with low scan speed such as keyhole, are presented in this work, and their effects on fatigue strength, density, and hardness of AlSi10Mg alloy are discussed. The overlap and isolated samples have a similar microstructure with little difference grain size and slight difference in strengths. The laser density as main influence on the mechanical properties and defects are formed when the laser energy density is too high or too low (such as defects, porosity, and micro crack). To avoid the defects (pores, cracks) and achieve full dense part 98% with laser power as 250 W, scan speed as 500 mm/s, hatch spacing as 80µm, and with layer thickness of 30 µm.

Keywords: Additive Manufacturing; Laser Powder Bed Fusion; Selective Laser Melting; AlSi10Mg Alloy; Thermal Simulation; Fatigue Strength; Microstructure; Porosity Defects; Density and Hardness