Selective Laser Melting AlSi12 Alloy by Utilizing of Non-Spherical Air-Atomized Powder

Abstract:

AlSi12 alloy is one of the most widely used materials in selective laser melting. Selective laser melting (SLM) of AlSi12 alloy has been well studied in recent years. Researchers typically use very expensive spherical powders atomized in an inert atmosphere. For this paper, we studied SLM of air-atomized non-spherical powder to determine its printability. Nine specimens were fabricated using different SLM process parameters. The lowest porosity that was achieved was 1.3%.

• Periodical: Solid State Phenomena (Volume 316)
• Pages: 558-563
• DOI: https://doi.org/10.4028/www.scientific.net/SSP.316.558
• Online since: April 2021
• Authors: R.M. Baitimerov*, A.V. Bryk
• Keywords: Additive Technologies, Aluminum Alloy, Metal Powder, Selective Laser Melting (SLM)

References

[1] B. Song, X. Zhao, S. Li, C. Han, Q. Wei, S. Wen, J. Liu, Y. Shi, Differences in microstructure and properties between selective laser melting and traditional manufacturing for fabrication of metal parts: A review, Front. Mech. Eng. 10 (2015) 111–125.

DOI: 10.1007/s11465-015-0341-2

[2] H. Fayazfar, M. Salarian, A. Rogalsky, D. Sarker, P. Russo, V. Paserin, E. Toyserkani, A critical review of powder-based additive manufacturing of ferrous alloys: Process parameters, microstructure and mechanical properties, Mater. Des. 144 (2018) 98–128.

DOI: 10.1016/j.matdes.2018.02.018

[3] H. Lee, C.H.J. Lim, M.J. Low, N. Tham, V.M. Murukeshan, Y.-J. Kim, Lasers in additive manufacturing: A review, Int. J. Precis. Eng. Manuf. - Green Technol. 4 (2017) 307–322.

DOI: 10.1007/s40684-017-0037-7

[4] P. Szymczyk, G. Ziółkowski, A. Junka, E. Chlebus, Application of Ti6Al7Nb alloy for the manufacture of biomechanical functional structures (BFS) for custom-made bone implants, Materials (Basel). 11 (2018).

DOI: 10.3390/ma11060971

[5] R.M. Baitimerov, P.A. Lykov, L.V. Radionova, E.V. Safonov, Parameter optimization for selective laser melting of TiAl6V4 alloy by CO2 laser, IOP Conf. Ser. Mater. Sci. Eng. 248 (2017).

DOI: 10.1088/1757-899x/248/1/012012

[6] D. Wang, S. Wu, Y. Yang, W. Dou, S. Deng, Z. Wang, S. Li, The effect of a scanning strategy on the residual stress of 316L steel parts fabricated by selective laser melting (SLM), Materials (Basel). 11 (2018).

DOI: 10.3390/ma11101821

[7] C. Haase, J. Bültmann, J. Hof, S. Ziegler, S. Bremen, C. Hinke, A. Schwedt, U. Prahl, W. Bleck, Exploiting process-related advantages of selective laser melting for the production of high-manganese steel, Materials (Basel). 10 (2017).

DOI: 10.3390/ma10010056

[8] P.A. Lykov, R.M. Baitimerov, S.D. Vaulin, Influence of SLM Process Parameters on Porosity of Nickel Base Heat Resistance Alloy EP648, Mater. Sci. Forum. 843 (2016) 253–258.

DOI: 10.4028/www.scientific.net/msf.843.253

[9] Q. Jia, D. Gu, Selective laser melting additive manufactured Inconel 718 superalloy parts: High-temperature oxidation property and its mechanisms, Opt. Laser Technol. 62 (2014) 161–171.

DOI: 10.1016/j.optlastec.2014.03.008

[10] X. Han, T. Sawada, C. Schille, E. Schweizer, L. Scheideler, J. Geis-Gerstorfer, F. Rupp, S. Spintzyk, Comparative analysis of mechanical properties and metal-ceramic bond strength of Co-Cr dental alloy fabricated by different manufacturing processes, Materials (Basel). 11 (2018).

DOI: 10.3390/ma11101801

[11] Z. Guoqing, Y. Yongqiang, L. Hui, S. Changhui, Z. Zimian, Study on the Quality and Performance of CoCrMo Alloy Parts Manufactured by Selective Laser Melting, J. Mater. Eng. Perform. 26 (2017) 2869–2877.

DOI: 10.1007/s11665-017-2716-5

[12] H. Attar, M. Calin, L.C. Zhang, S. Scudino, J. Eckert, Manufacture by selective laser melting and mechanical behavior of commercially pure titanium, Mater. Sci. Eng. A. 593 (2014) 170–177.

DOI: 10.1016/j.msea.2013.11.038

[13] P. Lykov, R. Baytimerov, S. Vaulin, E. Safonov, D. Zherebtsov, Selective Laser Melting of Copper by 200 W CO2 Laser, SAE Tech. Pap. 2016-April (2016).

DOI: 10.4271/2016-01-0333

[14] J. Li, Z. Zhao, P. Bai, H. Qu, M. Liang, H. Liao, L. Wu, P. Huo, Tribological behavior of TiC particles reinforced 316Lss composite fabricated using selective laser melting, Materials (Basel). 16 (2019).

DOI: 10.3390/ma12060950

[15] P.A. Lykov, S.B. Sapozhnikov, R.M. Baitimerov, The manufacturing of the AlSi12-Al2O3 composite powder for additive production methods, (2016).

DOI: 10.4028/www.scientific.net/msf.870.314

[16] F. Chang, D. Gu, D. Dai, P. Yuan, Selective laser melting of in-situ Al4SiC4 + SiC hybrid reinforced Al matrix composites: Influence of starting SiC particle size, Surf. Coatings Technol. 272 (2015) 15–24.

DOI: 10.1016/j.surfcoat.2015.04.029

[17] K.G. Prashanth, R. Damodaram, S. Scudino, Z. Wang, K. Prasad Rao, J. Eckert, Friction welding of Al-12Si parts produced by selective laser melting, Mater. Des. 57 (2014) 632–637.

DOI: 10.1016/j.matdes.2014.01.026

[18] H. Gu, H. Gong, J.J.S. Dilip, D. Pal, A. Hicks, H. Doak, B. Stucker, Effects of Powder Variation on the Microstructure and Tensile Strength of Ti6Al4V Parts Fabricated by Selective Laser Melting, Proc. 25th Solid Free. Fabr. Symp. Present. Int. Solid Free. Fabr. Symp. Austin, Texas, USA. (2014) 470–483.

[19] A.B. Spierings, N. Herres, G. Levy, Influence of the particle size distribution on surface quality and mechanical properties in additive manufactured stainless steel parts, Proc. 21st Solid Free. Fabr. Symp. Present. Int. Solid Free. Fabr. Symp. Austin, Texas, USA. (2010) 397–406.

DOI: 10.1108/13552541111124770

[20] R. Engeli, T. Etter, S. Hövel, K. Wegener, Processability of different IN738LC powder batches by selective laser melting, J. Mater. Process. Technol. 229 (2016) 484–491.

DOI: 10.1016/j.jmatprotec.2015.09.046

[21] P.A. Lykov, E. V Safonov, A.O. Shul'ts, Powder particle formation mechanism with dispersion of different molten metals, Metallurgist. 57 (2013) 232–236.

DOI: 10.1007/s11015-013-9717-x

[22] A.B. Spierings, M. Voegtlin, K. Wegener, T. Bauer, Powder flowability characterisation methodology for powder-bed- based metal additive manufacturing, Prog. Addit. Manuf. (2015).

DOI: 10.1007/s40964-015-0001-4

[23] X.P. Li, K.M. O'Donnell, T.B. Sercombe, Selective laser melting of Al-12Si alloy: Enhanced densification via powder drying, Addit. Manuf. 10 (2016) 10–14.

DOI: 10.1016/j.addma.2016.01.003

[24] D. Gu, Y. Shen, Balling phenomena during direct laser sintering of multi-component Cu-based metal powder, J. Alloys Compd. 432 (2007) 163–166.

DOI: 10.1016/j.jallcom.2006.06.011

[25] K.G. Prashanth, S. Scudino, H.J. Klauss, K.B. Surreddi, L. Löber, Z. Wang, A.K. Chaubey, U. Kühn, J. Eckert, Microstructure and mechanical properties of Al-12Si produced by selective laser melting: Effect of heat treatment, Mater. Sci. Eng. A. 590 (2014) 153–160.

DOI: 10.1016/j.msea.2013.10.023

[26] K.G. Prashanth, J. Eckert, Formation of metastable cellular microstructures in selective laser melted alloys, J. Alloys Compd. 707 (2017) 27–34.

DOI: 10.1016/j.jallcom.2016.12.209