Porosity Inducing Process Parameters in Selective Laser Melted AlSi10Mg Aluminium Alloy

Abstract

Additive manufacturing techniques are known for the unrivalled geometric freedom they offer to designers. It is one of the mainstays of “metal 3D-printing”, compared to casting, which, in contrast, implies more restrictions because some shapes do not cool evenly or may need moulds or forms. Despite the possible presence of defects inside additive manufactured components, such as oxide films, pores or unmelted powder, they can be strongly reduced or controlled by process parameters optimization. That seems not true for a casting component, in which defects can vary a lot from zone to zone according to the solidification conditions. Porosity inducing process parameters in selective laser melted AlSi10Mg aluminium alloy are carefully analysed with the aim to find optimal conditions that guarantee the maximum material density and the best mechanical properties. Finally, a model is proposed that correlates the amount of pores with the alloy ultimate tensile strength.