Optimization of the lost PLA production process for the manufacturing of Al-alloy porous structures: Recent developments, macrostructural and microstructural analysis

The main task of this work is the optimization of the manufacturing process of Al-alloy lattice cellular structures with rhombic cell, obtained with lost-PLA technique. It is an easy, environment sustainable and economical technique (both for infrastructure and operating costs) for the manufacturing of Al porous structure based on the 3D printing of PLA and replication process alternative to that based on expensive metal 3D printers. Plaster processing, PLA burnout and AA 6082 alloy casting conditions and parameters have been suitably tuned in order to get final samples with geometry and surface finishing conditions identical to the starting ones made in PLA. A good replication process has been implemented with a high repeatability rate and accurate surface finishing, comparable with that of the PLA printed objects. Morphological analysis on PLA and Al 6082 was conducted as well microstructural analysis and Vickers microhardness tests on Al alloy samples in the as-cast conditions. Metallography reveals the presence of AlFeSi and AlFeMnSi intermetallic phases at the cell boundaries and some coarse precipitates Mg₂Si in the AA 6082 alloy. Microstructures and HV measured values are aligned with literature data for this alloy in the same (as-cast) conditions.