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Cryogenic Machining of a Laser Powder Bed Fusion-Processed AlSi7Mg Aluminum Alloy

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Abstract:

Additive manufacturing by laser powder bed fusion (LPBF) is increasingly applied to aluminium alloys; however, the resulting surface quality and machining behaviour remain critical challenges, particularly when post-processing is required. In this context, the interaction between LPBF process parameters and advanced cooling strategies during machining remains largely unexplored.This study examines the impact of cryogenic machining on the surface integrity of LPBF-produced AlSi7Mg components, fabricated with varying layer thicknesses. Specimens were machined under fixed cutting parameters using either conventional flood cooling or cryogenic cooling. Cutting forces, surface roughness, defect morphology, and subsurface microstructure were systematically evaluated.Cryogenic cooling consistently reduced cutting forces and improved surface quality, effectively suppressing tearing formation. In contrast, under flood cooling, the influence of the microstructural differences induced by layer thickness remained significant, with increasing LPBF layer thickness further enhancing both surface and subsurface integrity. Overall, the results reveal a strong interaction between LPBF parameters and cooling strategy, highlighting the unexpectedly beneficial role of cryogenic machining in improving the surface integrity of LPBF-processed AlSi7Mg alloys.

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Periodical:

Defect and Diffusion Forum (Volume 450)

Pages:

31-39

DOI:

https://doi.org/10.4028/p-9AOMkv

Citation:

Cite this paper

Online since:

April 2026

Authors:

Rachele Bertolini*, Toushiqul Islam, Shuaihang Pan, Edoardo Ghinatti, Stefania Bruschi

Keywords:

Aluminum Alloy, EBSD, Laser Powder Bed Fusion, Layer Thickness, Machinability, Surface Integrity

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Creative Commons CC BY 4.0

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* - Corresponding Author

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