Numerical prediction of lack-of-fusion defects in selective laser melted AlSi10Mg alloy

Abstract

Despite the emerging research, it is still troublesome to control the defect formation in selective laser melted parts. In this paper, a mechano-thermo-fluid dynamical FEM model at meso-scale was proposed. The model calculates and predicts the volume and dimensions of lack-of-fusion (LOF) defects according to the applied process parameters. The numerical model was validated with experimentally assessed volume of lack-of-fusion defects and melt pool dimensions. Results shown the lowest volume of LOF defects (0.41%) in specimen produced with 275 W and scanning speed of 400 mm/s. Laser power was determined as a parameter majorly impacting the volume and dimensions of LOF in selective laser melted parts.

KEYWORDS:

• SLM
• lack-of-fusion
• porosity
• melt pool dimensions

Acknowledgement

The authors gratefully acknowledge prof. Fabrizia Caiazzo from University of Salerno, 84084 Fisciano (SA), Italy for providing the Selective Laser Melted specimens.

Disclosure statement

No potential conflict of interest was reported by the author(s).

Authors’ contributions

Tests, material preparation, data collection and analysis were performed by all authors. All authors read and approved the final manuscript.