Comprehensive review of fabrication process parameters influencing defect formation in laser powder bed fused (L-PBF) Al-Si alloys

Abstract

Recently, Laser Powder Bed Fusion (L-PBF) has garnered considerable interest for its ability to fabricate highly precise and intricate Al-Si alloy components. Its versatility in design makes it particularly appealing for industries such as aerospace and automotive, where lightweight structures are critical. However, the L-PBF process induces defects in the resulting components, such as solidification cracks, porosity, anisotropy, and uneven surfaces, which compromise structural integrity and dimensional accuracy. As a result, significant effort has been devoted to understanding how fabrication parameters influence defect formation in L-PBF Al-Si parts. Despite extensive research on laser material processing, a comprehensive understanding of how specific process parameters affect defect formation remains limited. This knowledge is crucial for optimizing the performance of L-PBF Al-Si components. This article aims to provide a systematic examination of the causes of defects in L-PBF Al-Si components and their relationship with fabrication factors and process parameters. Additionally, it offers insights into addressing these challenges and highlights future research directions to mitigate defects in L-PBF Al-Si components. Consequently, this work aims to further promote the development of L-PBF-manufactured Al-Si components and their widespread applications across diverse industries.