Fabrication and mechanical properties of Al–Si-based alloys by selective laser melting process

ABSTRACT

Aluminium (Al)-based alloys have attracted as promising materials for structural applications using metal 3D printing due to their excellent specific mechanical strength, formability, and durability. In this study, highly flowable coarse AlSi10Mg powders with average diameter of 65 µm were prepared and then they were additively manufactured by using the selective laser melting (SLM) process. The relative densities exceeding 99% were consistently obtained from the samples fabricated at the scan speed of 1000–2000 mm·s⁻¹ in the range of laser power from 350 to 390 W. The tensile strengths and elongation of all the samples were characterised. Furthermore, Al alloy processed by coarse AlSi10Mg powders does not show a big change in strength values compared to those fabricated by fine AlSi10Mg powders with 45 µm in diameter. Thus, these results clearly show that the developed coarse AlSi10Mg powders can be effectively utilised for the SLM process.

KEYWORDS:

• AlSi10Mg
• powder size
• additive manufacturing
• SLM

Acknowledgements

This study was supported by the R&D project entitled ‘Development for car body lightweighting and material localisation using 3D Printing technology (Project No: 20004486)’ by the Ministry of Trade, Industry and Energy of the Republic of Korea.

Disclosure statement

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

Additional information

Funding

This work was supported by Ministry of Trade, Industry and Energy (KR): [Grant Number 20004486].

Notes on contributors

Yeong Seong Eom

Yeong Seong Eom is currently working as a Ph.D. student at the Department for 3D Printing Materials, Korea institute of Materials Science, Korea.

Kyung Tae Kim

Kyung Tae Kim is currently working as a senior researcher at the Department for 3D Printing Materials, Korea institute of Materials Science, Korea. His main research activity is devoted to surface science, powder metallurgy and additive manufacturing.

Dong Won Kim

Dong Won Kim is currently working as a senior researcher at the Department for 3D Printing Materials, Korea institute of Materials Science, Korea. His main research activity is devoted to surface science, powder metallurgy and additive manufacturing.

Soo ho Jung

Soo ho Jung is currently working as a senior researcher at the Department for 3D Printing Materials, Korea institute of Materials Science, Korea. His main research activity is devoted to surface science, powder metallurgy and additive manufacturing.

Jung Woo Nam

Jung Woo Nam is currently working as a M.E. student at the Department for 3D Printing Materials, Korea institute of Materials Science, Korea.

Dong Yeol Yang

Dong Yeol Yang is currently working as a senior researcher at the Department for 3D Printing Materials, Korea institute of Materials Science, Korea. His main research activity is devoted to surface science, powder metallurgy and additive manufacturing.

Jungho Choe

Jungho Choe is currently working as a researcher at the Department for 3D Printing Materials, Korea institute of Materials Science, Korea. His main research activity is devoted to surface science, powder metallurgy and additive manufacturing.

Ji Hun Yu

Ji Hoon Yu is currently working as a senior researcher at the Department for 3D Printing Materials, Korea institute of Materials Science, Korea. His main research activity is devoted to surface science, powder metallurgy and additive manufacturing.

Injoon Son

Injoon Son is currently a full professor at the Department of Metallurgical Engineering, Kyungpook National University, Korea.