Effect of Layer Thickness on Forming Quality and Efficiency of AlSi10Mg Alloy Fabricated by Selective Laser Melting

Taiqi Yan; Bingqing Chen; Pengjun Tang; Ruikun Chu; Shaoqing Guo

doi:10.3788/CJL202148.1002106

Chinese Journal of Lasers, Volume. 48, Issue 10, 1002106(2021)

Effect of Layer Thickness on Forming Quality and Efficiency of AlSi10Mg Alloy Fabricated by Selective Laser Melting

Taiqi Yan¹, Bingqing Chen^1、*, Pengjun Tang¹, Ruikun Chu², and Shaoqing Guo¹

¹3D Printing Research and Engineering Technology Center, AECC Beijing Institute of Aeronautical Materials, Beijing 100095, China

²Falcon Fast Manufacturing Technology Co,. Ltd., Wuxi, Jiangsu 214145, China

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Figures & Tables(18)

Fig. 1. Morphology of the AlSi10Mg alloy powder. (a) ×200; (b) ×500

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Fig. 2. Particle size distribution of the AlSi10Mg alloy powder

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Fig. 3. Image of the partially formed sample

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Fig. 4. Relative density and corresponding energy density of AlSi10Mg alloy sample under 30 μm layer thickness

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Fig. 5. Relative density and corresponding energy density of AlSi10Mg alloy sample under 60 μm layer thickness

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Fig. 6. Room temperature strength and plasticity of AlSi10Mg alloy samples with different layer thicknesses. (a) X/Y direction; (b) Z direction

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Fig. 7. Metallographic diagrams of samples with different layer thicknesses. (a) Layer thickness is 30 μm, X/Y direction; (b) layer thickness is 30 μm, Z direction; (c) layer thickness is 60 μm, X/Y direction; (d) layer thickness is 60 μm, Z direction

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Fig. 8. Overlapping areas of the molten pool with different layer thicknesses. (a) Layer thickness is 30 μm; (b) layer thickness is 60 μm

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Fig. 9. FESEM images of AlSi10Mg alloy samples with different layer thicknesses (X/Y direction). (a) Layer thickness is 30 μm, inside the molten pool; (b) layer thickness is 30 μm, boundary the molten pool; (c) layer thickness is 60 μm, inside the molten pool; (d) layer thickness is 60 μm, boundary the molten pool

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$Macroscopic tensile fracture morphology of AlSi10Mg alloy samples with different layer thicknesses. (a) Layer thickness is 30 μm, X/Y direction; (b) layer thickness is 30 μm, Z direction; (c) layer thickness is 60 μm, X/Y direction; (d) layer thickness is 60 μm, Z direction$

Fig. 10. Macroscopic tensile fracture morphology of AlSi10Mg alloy samples with different layer thicknesses. (a) Layer thickness is 30 μm, X/Y direction; (b) layer thickness is 30 μm, Z direction; (c) layer thickness is 60 μm, X/Y direction; (d) layer thickness is 60 μm, Z direction

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$Microscopic tensile fracture morphology of AlSi10Mg alloy samples with different layer thicknesses. (a) Layer thickness is 30 μm, X/Y direction; (b) layer thickness is 30 μm, Z direction; (c) layer thickness is 60 μm, X/Y direction; (d) layer thickness is 60 μm, Z direction$

Fig. 11. Microscopic tensile fracture morphology of AlSi10Mg alloy samples with different layer thicknesses. (a) Layer thickness is 30 μm, X/Y direction; (b) layer thickness is 30 μm, Z direction; (c) layer thickness is 60 μm, X/Y direction; (d) layer thickness is 60 μm, Z direction

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Table 1. Mass fraction of element in AlSi10Mg alloy powder unit: %
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Table 1. Mass fraction of element in AlSi10Mg alloy powder unit: %
Element Al Si Mg Ti Ni Mn Cu Fe Zn Pb Sn O
Mass fraction balance 10.00 0.34 <0.01 <0.01 <0.01 <0.01 0.034 <0.01 <0.01 <0.01 0.070

Table 2. Process parameters of the SLM forming
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Table 2. Process parameters of the SLM forming
No. Layer thickness /μm Spot diameter /mm Laser power /W Scanning speed /(mm·s^-1) Hatch spacing /mm
1 30 0.1 350 1400--1800 0.16
2 60 0.2 890 1600--2000 0.20

Table 3. Process parameters, energy density and relative density of AlSi10Mg alloy sample under 30 μm layer thickness

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Table 3. Process parameters, energy density and relative density of AlSi10Mg alloy sample under 30 μm layer thickness

Layer thickness /μm	Spot diameter /mm	Laser power /W	Hatch spacing /mm	Scanning speed /(mm·s^-1)	Energy density /(J·mm^-3)	Relative density /%
30	0.1	350	0.16	1400	52.08	98.88
				1500	48.61	98.88
				1600	45.57	99.25
				1700	42.89	99.25
				1800	40.51	98.88

Table 4. Process parameters, energy density and relative density of AlSi10Mg alloy sample under 60 μm layer thickness

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Table 4. Process parameters, energy density and relative density of AlSi10Mg alloy sample under 60 μm layer thickness

Layer thickness /μm	Spot diameter /mm	Laser power /W	Hatch spacing /mm	Scanning speed /(mm·s^-1)	Energy density /(J·mm^-3)	Relative density /%
60	0.2	890	0.20	1600	46.35	98.88
				1700	43.63	99.25
				1800	41.20	99.25
				1900	39.04	99.25
				2000	37.08	98.88

Table 5. Parameters of AlSi10Mg alloy samples under different layer thicknesses

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Table 5. Parameters of AlSi10Mg alloy samples under different layer thicknesses

Layerthickness /μm	Spotdiameter /mm	Laserpower /W	Hatchspacing /mm	Scanningspeed /(mm·s^-1)	Energydensity /(J·mm^-3)	Relativedensity /%	Tensilestrength /MPa		Elongation /%
Layerthickness /μm	Spotdiameter /mm	Laserpower /W	Hatchspacing /mm	Scanningspeed /(mm·s^-1)	Energydensity /(J·mm^-3)	Relativedensity /%	X/Y	Z	X/Y	Z
30	0.1	350	0.16	1600	45.57	99.25	283.7	292.3	13.84	13.07
60	0.2	890	0.20	1700	43.63	99.25	276.8	285.1	14.36	9.97

Table 6. Hole sizes of AlSi10Mg alloy samples under different layer thicknesses
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Table 6. Hole sizes of AlSi10Mg alloy samples under different layer thicknesses
Layerthickness /μm Hole size /μm Average value /μm
1 2 3 4
30 5.6 6.1 6.1 7.4 6.2
60 7.0 7.7 8.8 8.9 8.1

Table 7. Forming rates of AlSi10Mg alloy samples with optimized process parameters under different thicknesses
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Table 7. Forming rates of AlSi10Mg alloy samples with optimized process parameters under different thicknesses
Layerthickness /μm Spotdiameter /mm Laserpower /W Scanning speed /(mm·s^-1) Hatch spacing /mm Energy density /(J·mm^-3) Forming rate /(mm³·s^-1)
30 0.1 350 1600 0.16 45.57 7.68
60 0.2 890 1700 0.20 43.63 20.40

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Taiqi Yan, Bingqing Chen, Pengjun Tang, Ruikun Chu, Shaoqing Guo. Effect of Layer Thickness on Forming Quality and Efficiency of AlSi10Mg Alloy Fabricated by Selective Laser Melting[J]. Chinese Journal of Lasers, 2021, 48(10): 1002106

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Paper Information

Category: Laser Material Processing

Received: Jul. 28, 2020

Accepted: Oct. 27, 2020

Published Online: Apr. 27, 2021

The Author Email: Chen Bingqing (hwtkjcbq1984@163.com)

DOI:10.3788/CJL202148.1002106

Topics

laser devices and laser physics

Lasers and Laser Optics

Laser physics

laser manufacturing

Instrumentation, Measurement and Metrology

Table 1. Mass fraction of element in AlSi10Mg alloy powder unit: %

Table 1. Mass fraction of element in AlSi10Mg alloy powder unit: %

Table 2. Process parameters of the SLM forming

Table 2. Process parameters of the SLM forming

Table 3. Process parameters, energy density and relative density of AlSi10Mg alloy sample under 30 μm layer thickness

Table 3. Process parameters, energy density and relative density of AlSi10Mg alloy sample under 30 μm layer thickness

Table 4. Process parameters, energy density and relative density of AlSi10Mg alloy sample under 60 μm layer thickness

Table 4. Process parameters, energy density and relative density of AlSi10Mg alloy sample under 60 μm layer thickness

Table 5. Parameters of AlSi10Mg alloy samples under different layer thicknesses

Table 5. Parameters of AlSi10Mg alloy samples under different layer thicknesses

Table 6. Hole sizes of AlSi10Mg alloy samples under different layer thicknesses

Table 6. Hole sizes of AlSi10Mg alloy samples under different layer thicknesses

Table 7. Forming rates of AlSi10Mg alloy samples with optimized process parameters under different thicknesses

Table 7. Forming rates of AlSi10Mg alloy samples with optimized process parameters under different thicknesses