Microstructure and mechanical properties of parts produced by laser powder bed fusion of AlSi10Mg powder with coarse particle size

IF 5.5 2区 材料科学 Q1 MATERIALS SCIENCE, CHARACTERIZATION & TESTING
F.N. Depboylu , O.V. Mishin , T. Leissner , A.A. Popa
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Abstract

Powder size and morphology play a central role in laser powder bed fusion of metallic components, influencing the process stability, microstructure, and mechanical properties. In the pursuit of more efficient production, coarse powders (∼90 μm and greater) have become commercially available, enabling increased layer thickness and build rate. For AlSi10Mg, only limited data exist on how such coarse powders perform during additive manufacturing in medium-wattage (400 W) systems and on what microstructures and mechanical properties can be achieved in parts 3D-printed using these powders. The present study addresses this gap by characterizing parts produced using NExP-1 AlSi10Mg, a novel non-combustible and non-explosible powder with uniform spherical morphology and a median size of ∼90 μm. The microstructure and tensile properties have been assessed in samples manufactured using three distinct combinations of process parameters, resulting in relative densities of 97.5–99.6 % (measured using Archimedes' principle). Results obtained in this study show that an increased hatch distance at a low scan speed significantly reduces the relative density due to lack-of-fusion porosity, which leads to decreased strength and ductility compared to those in a sample with the highest density. The pore population characterized using micro-computed tomography is found to be related to sample density: the highest-density sample primarily contains isolated pores, whereas lower-density samples display higher frequences of interconnected pores. This work provides new insights into the potential of coarse AlSi10Mg powders and serves as the basis for further process optimization for demanding industrial applications.
粗粒度AlSi10Mg粉末激光粉末床熔接零件的组织与力学性能
粉末的尺寸和形貌在激光粉末床熔接金属部件的过程中起着核心作用,影响着过程的稳定性、微观结构和力学性能。为了追求更高效的生产,粗粉(~ 90 μm及更大)已经商品化,可以增加层厚度和构建速率。对于AlSi10Mg,只有有限的数据存在于这种粗粉末在中瓦数(400 W)系统中的增材制造过程中如何表现,以及使用这些粉末在3d打印部件中可以实现哪些微观结构和机械性能。本研究通过表征使用NExP-1 AlSi10Mg生产的零件来解决这一空白,NExP-1 AlSi10Mg是一种新型的不燃不爆粉末,具有均匀的球形形貌,中位尺寸为~ 90 μm。使用三种不同的工艺参数组合对样品的微观结构和拉伸性能进行了评估,得到的相对密度为97.5 - 99.6%(使用阿基米德原理测量)。本研究的结果表明,在低扫描速度下,由于缺乏熔合孔隙,增加的舱口距离显著降低了相对密度,导致强度和延展性与密度最高的样品相比有所下降。微观计算机断层扫描表征的孔隙密度与样品密度有关:最高密度的样品主要包含孤立的孔隙,而低密度的样品显示出更高频率的相互连接的孔隙。这项工作为AlSi10Mg粗粉的潜力提供了新的见解,并为要求苛刻的工业应用的进一步工艺优化奠定了基础。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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来源期刊
Materials Characterization
Materials Characterization 工程技术-材料科学:表征与测试
CiteScore
7.60
自引率
8.50%
发文量
746
审稿时长
36 days
期刊介绍: Materials Characterization features original articles and state-of-the-art reviews on theoretical and practical aspects of the structure and behaviour of materials. The Journal focuses on all characterization techniques, including all forms of microscopy (light, electron, acoustic, etc.,) and analysis (especially microanalysis and surface analytical techniques). Developments in both this wide range of techniques and their application to the quantification of the microstructure of materials are essential facets of the Journal. The Journal provides the Materials Scientist/Engineer with up-to-date information on many types of materials with an underlying theme of explaining the behavior of materials using novel approaches. Materials covered by the journal include: Metals & Alloys Ceramics Nanomaterials Biomedical materials Optical materials Composites Natural Materials.
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