Defects, Mechanical Properties and Surface Roughness of AlSi10Mg Alloy Parts Produced by Selective Laser Melting (SLM) Method-A Review

Abstract

Metal-based additive manufacturing is a modern manufacturing process in which three-dimensional (3D) objects are fabricated by layer-by-layer melting of metallic powder or wire with an energy source. Selective laser melting (SLM) method is used in both scientific and industrial fields as it allows the production of complex and light structures. AlSi10Mg alloy is widely used in aerospace, automotive, marine and medical industries, as well as in various applications that require special designs and is one of the prominent materials in SLM research. The quality of a product produced by the SLM method requires optimization of manufacturing parameters (laser power, scanning speed, scanning distance, layer thickness) that affect the energy density required for melting. With the use of inappropriate manufacturing parameters, internal stresses arising from deformation mechanisms occur due to the process and distortion, cracking and dimensional changes occur on the part. Variables such as powder material properties, uneven distribution of powder layer, deformation during manufacturing, changes in laser beam can cause metallurgical pores. Any defects that occur in the manufacturing process have a negative effect on the mechanical properties and surface quality of the final part. In this study, the results obtained by researching the studies in the literature to produce parts with high density, high strength properties and high surface quality from AlSi10Mg alloy by selective laser melting method are presented. As a result of the research, it has been determined that energy density is more decisive on product quality. It has been determined that the ideal energy density for the least porosity in the products is in the range of 50-75 J/mm3, and the AlSi10Mg alloy parts produced by additive manufacturing show better strength properties compared to those produced by the casting method.

Keywords

• Additive manufacturing
• Manufacturing parameters
• Porosity
• Mechanical properties
• Surface roughness

Seçici Lazer Ergitme (SLM) Yöntemi ile Üretilen AlSi10Mg Alaşımlı Parçalarda Kusurlar, Mekanik Özellikler ve Yüzey Pürüzlülüğü-Bir Araştırma

Öz

Metal esaslı eklemeli imalat, bir enerji kaynağı ile metalik tozun veya telin katman katman eritilmesi yoluyla üç boyutlu (3B) nesnelerin imal edildiği modern bir üretim sürecidir. Seçici lazer eritme (SLM) yöntemi, karmaşık ve hafif yapıların üretimine olanak sağladığından hem bilimsel hem de endüstriyel alanlarda kullanılmaktadır. AlSi10Mg alaşımı havacılık, otomotiv, denizcilik ve medikal endüstrilerin yanı sıra, özel tasarımlara ihtiyaç duyulan çeşitli uygulamalarda yaygın olarak kullanılmakta ve SLM araştırmalarında öne çıkan malzemelerden biri durumundadır. SLM yöntemi ile üretilen bir ürünün kalitesi, ergitme için gerekli olan enerji yoğunluğunu etkileyen imalat parametrelerinin (lazer gücü, tarama hızı, tarama mesafesi, katman kalınlığı) optimizasyonunu gerektirmektedir. Uygun olmayan imalat parametrelerinin kullanılması ile süreç gereği deformasyon mekanizmalarından kaynaklanan iç gerilmeler oluşmakta ve parça üzerinde çarpılma, çatlama ve boyutsal değişim meydana gelmektedir. Toz malzeme özellikleri, toz tabakasının düzgün olmayan dağıtımı, imalat sırasında deformasyon, lazer ışınındaki değişiklikler gibi değişkenler metalurjik gözeneklere neden olabilmektedir. İmalat sürecinde oluşan her türlü kusur nihai parçanın mekanik özellikleri ve yüzey kalitesi üzerinde olumsuz etkiye sahiptir. Bu çalışmada seçici lazer ergitme yöntemi ile AlSi10Mg alaşımından yüksek yoğunlukta, yüksek mukavemet özelliklerinde ve yüksek yüzey kalitesinde parçalar üretmek için literatürde yapılan çalışmalar araştırılarak elde edilen sonuçlar sunulmuştur. Araştırma sonucunda, enerji yoğunluğunun ürün kalitesi üzerinde daha belirleyici olduğu tespit edilmiştir. Ürünlerde en az gözeneklilik için ideal enerji yoğunluğunun 50-75 J/mm3 aralığında olduğu, eklemeli imalat ile üretilen AlSi10Mg alaşımlı parçaların döküm yöntemi ile üretilenlere kıyasla daha iyi mukavemet özelliği gösterdiği belirlenmiştir.

Anahtar Kelimeler

• Eklemeli imalat
• İmalat parametreleri
• Gözeneklilik
• Mekanik özellikler
• Yüzey pürüzlülüğü

Kaynakça

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