Effect of Scan Strategies and Use of Support Structures on Surface Quality and Hardness of L-PBF AlSi10Mg Parts
Additive manufacturing allows for a great degree of design freedom and is rapidly becoming a mainstream manufacturing process. However, as in all manufacturing processes, it has its limitations and specificities. Equipping engineers with this knowledge allows for a higher degree of optimization, ext...
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doaj-0e0103d0a7ef4784b71b675caf06ccf02020-11-25T02:04:22ZengMDPI AGMaterials1996-19442020-05-01132248224810.3390/ma13102248Effect of Scan Strategies and Use of Support Structures on Surface Quality and Hardness of L-PBF AlSi10Mg PartsRonny M. Gouveia0Francisco J. G. Silva1Eleonora Atzeni2Dušan Sormaz3Jorge Lino Alves4António Bastos Pereira5ISEP—School of Engineering, Polytechnic of Porto, 4200-072 Porto, PortugalISEP—School of Engineering, Polytechnic of Porto, 4200-072 Porto, PortugalDipartimento di Ingegneria Gestionale e della Produzione, Politecnico di Torino, 10129 Torino, ItalyDepartment of Industrial and Systems Engineering, The Ohio University, Athens, OH 45701, USAFaculty of Engineering, University of Porto, 4200-465 Porto, PortugalTEMA—Centre for Mechanical Technology and Automation, Department of Mechanical Engineering, Campus de Santiago, University of Aveiro, 3810-193 Aveiro, PortugalAdditive manufacturing allows for a great degree of design freedom and is rapidly becoming a mainstream manufacturing process. However, as in all manufacturing processes, it has its limitations and specificities. Equipping engineers with this knowledge allows for a higher degree of optimization, extracting the most out of this technology. Therefore, a specific part design was devised and created via L-PBF (Laser Powder Bed Fusion) using AlSi10Mg powder. Certain parameters were varied to identify the influence on material density, hardness, roughness, residual stress and microstructures. It was found that on heat treated parts laser pattern strategy is one of the most influential aspects, showing that chessboard and stripes 67° improved outcome; average R<sub>a</sub> roughness varied between 8–12 µm, residual stress was higher on vertical surfaces than horizontal surfaces, with the combination of support structures and stripes 67° strategies generating the lowest residual stress (205 MPa on a lateral/vertical face), hardness was non-orientation dependent and larger on samples with chessboard fabrication strategies, while microstructures were composed of α–Al dendrites surrounded by Si particles. The distribution and grain size of the microstructure is dependent on location regarding melt pool and HAZ area. Furthermore, Al–Mg oxides were encountered on the surface, along with pores generating from lack of fusion.https://www.mdpi.com/1996-1944/13/10/2248additive manufacturing (AM)additive manufacturing materialsAlSi10Mgmicrostructureroughnessresidual stress |
collection |
DOAJ |
language |
English |
format |
Article |
sources |
DOAJ |
author |
Ronny M. Gouveia Francisco J. G. Silva Eleonora Atzeni Dušan Sormaz Jorge Lino Alves António Bastos Pereira |
spellingShingle |
Ronny M. Gouveia Francisco J. G. Silva Eleonora Atzeni Dušan Sormaz Jorge Lino Alves António Bastos Pereira Effect of Scan Strategies and Use of Support Structures on Surface Quality and Hardness of L-PBF AlSi10Mg Parts Materials additive manufacturing (AM) additive manufacturing materials AlSi10Mg microstructure roughness residual stress |
author_facet |
Ronny M. Gouveia Francisco J. G. Silva Eleonora Atzeni Dušan Sormaz Jorge Lino Alves António Bastos Pereira |
author_sort |
Ronny M. Gouveia |
title |
Effect of Scan Strategies and Use of Support Structures on Surface Quality and Hardness of L-PBF AlSi10Mg Parts |
title_short |
Effect of Scan Strategies and Use of Support Structures on Surface Quality and Hardness of L-PBF AlSi10Mg Parts |
title_full |
Effect of Scan Strategies and Use of Support Structures on Surface Quality and Hardness of L-PBF AlSi10Mg Parts |
title_fullStr |
Effect of Scan Strategies and Use of Support Structures on Surface Quality and Hardness of L-PBF AlSi10Mg Parts |
title_full_unstemmed |
Effect of Scan Strategies and Use of Support Structures on Surface Quality and Hardness of L-PBF AlSi10Mg Parts |
title_sort |
effect of scan strategies and use of support structures on surface quality and hardness of l-pbf alsi10mg parts |
publisher |
MDPI AG |
series |
Materials |
issn |
1996-1944 |
publishDate |
2020-05-01 |
description |
Additive manufacturing allows for a great degree of design freedom and is rapidly becoming a mainstream manufacturing process. However, as in all manufacturing processes, it has its limitations and specificities. Equipping engineers with this knowledge allows for a higher degree of optimization, extracting the most out of this technology. Therefore, a specific part design was devised and created via L-PBF (Laser Powder Bed Fusion) using AlSi10Mg powder. Certain parameters were varied to identify the influence on material density, hardness, roughness, residual stress and microstructures. It was found that on heat treated parts laser pattern strategy is one of the most influential aspects, showing that chessboard and stripes 67° improved outcome; average R<sub>a</sub> roughness varied between 8–12 µm, residual stress was higher on vertical surfaces than horizontal surfaces, with the combination of support structures and stripes 67° strategies generating the lowest residual stress (205 MPa on a lateral/vertical face), hardness was non-orientation dependent and larger on samples with chessboard fabrication strategies, while microstructures were composed of α–Al dendrites surrounded by Si particles. The distribution and grain size of the microstructure is dependent on location regarding melt pool and HAZ area. Furthermore, Al–Mg oxides were encountered on the surface, along with pores generating from lack of fusion. |
topic |
additive manufacturing (AM) additive manufacturing materials AlSi10Mg microstructure roughness residual stress |
url |
https://www.mdpi.com/1996-1944/13/10/2248 |
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