Politeknik Dergisi 2147-9429 Gazi Üniversitesi 10.2339/politeknik.1777073 Mechanical Engineering (Other) Makine Mühendisliği (Diğer) LPBF Yöntemiyle Üretilen AlSi10Mg Çekme Numunelerinin Kırılma Yüzeylerindeki Kusur Mekanizmalarının Enerji Yoğunluğuna Bağlı Olarak SEM ve EDS ile İncelenmesi Investigation of Defect Mechanisms on Fracture Surfaces of LPBF-Produced AlSi10Mg Tensile Specimens Depending on Energy Density Using SEM and EDS https://orcid.org/0000-0001-8172-0832 Doğdu Nafel AKDENİZ ÜNİVERSİTESİ 03 29 2026 29 3 1 10 09 02 2025 11 01 2025 Copyright © 1998, Politeknik Dergisi 1998 Politeknik Dergisi

Bu çalışma, Lazer Toz Yatağı Füzyonu (LPBF) yöntemiyle üretilen AlSi10Mg alaşımlarında enerji yoğunluğunun kırılma davranışı ve mikroyapısal kusur oluşumu üzerindeki etkisini incelemektedir. Üç farklı enerji yoğunluğu seviyesinde üretilen çekme numuneleri, çekme testleri sonrasında Taramalı Elektron Mikroskobu (SEM) ve Enerji Dağılımlı Spektroskopi (EDS) yöntemleriyle analiz edilmiştir. Sonuçlar, düşük enerji yoğunluğu koşullarında birleşme eksiklikleri (LOF) ve ergimemiş partiküllerin, yüksek enerji yoğunluğunda ise gaz boşlukları ve oksit kapanımlarının belirgin şekilde arttığını göstermiştir. Orta enerji yoğunluğu aralığında en homojen mikroyapı, minimum porozite ve en yüksek çekme dayanımı elde edilmiştir. Bulgular, enerji yoğunluğu ile mekanik performans arasında doğrusal olmayan bir ilişki bulunduğunu ve optimum parametre aralığının mikroyapısal kusurları minimize ettiğini ortaya koymuştur. Bu durum, LPBF sürecinde üretim parametrelerinin hassas kontrolünün kırılma davranışının iyileştirilmesi açısından kritik önem taşıdığını göstermektedir.

This study investigates the effect of energy density on fracture behavior and microstructural defect formation in AlSi10Mg alloys produced by the Laser Powder Bed Fusion (LPBF) process. Tensile specimens manufactured at three different energy density levels were analyzed after tensile testing using Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS). The results revealed that lack of fusion defects (LOF) and unmelted particles were predominant at low energy density, while gas pores and oxide inclusions increased significantly at high energy density. At the medium energy density range, the most homogeneous microstructure, minimum porosity, and the highest tensile strength were achieved. The findings demonstrated a non-linear relationship between energy density and mechanical performance, showing that the optimum parameter range minimized microstructural defects. This highlights the critical importance of precise control of LPBF process parameters in improving fracture behavior.

 LPBF AlSi10Mg SEM EDS Enerji Yoğunluğu LPBF AlSi10Mg SEM EDS Energy Density [1] Cabrini M., Lorenzi S., Testa C., Manfredi D., Lombardi M., Aversa A., Andreatta F., Fedrizzi L., Dekhtyar Y., Sorokins H. and Pastore T., “Effect of heat treatment on microstructure and selective corrosion of LPBF-AlSi10Mg by means of SKPFM and exo-electron emission”, Materials, 14(19): 5602, (2021). [2] Chen H., Patel S., Vlasea M. and Zou Y., “Enhanced tensile ductility of an additively manufactured AlSi10Mg alloy by reducing the density of melt pool boundaries”, Scripta Materialia, 221: 114954, (2022). [3] Graf M., Fritsch S. and Awiszus B., “Determination of forming behaviour of EN AW-6060 by different testing methods under cold bulk forming conditions”, Procedia Manufacturing, 47: 1512–1519, (2020). [4] Hyer H., Le Zhou S., Park G., Gottsfritz G., Benson B., Tolentino B., McWilliams B. Cho K. and Sohn Y., “Understanding the laser powder bed fusion of AlSi10Mg alloy”, Metallography, Microstructure, and Analysis, 9(4): 484–502, (2020). [5] Işılak C., Esmer Ünal G., Yılmazoğlu G., Üzel U., Durgut R. and Uğuz A., “Eklemeli imalat ile üretilen AlSi10Mg plakalarının MIG yöntemiyle birleştirilmesi ve kaynak parametrelerinin optimizasyonu,” Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, 40(1): 573-586, (2024). [6] Jatti V., Saiyathibrahim A., Ramasamy M.K., Jatti A., Suganya Priyadharshini G. and Mohan D.G., “Investigating the effect of volumetric energy density on tensile characteristics of as‐built and heat‐treated AlSi10Mg alloy fabricated by laser powder bed fusion”, Advanced Engineering Materials, 27(4): 2401924, (2025). [7] Johnson Q.C., Laursen C.M., Spear A.D., Carroll J.D. and Noell P.J., “Analysis of the interdependent relationship between porosity, deformation, and crack growth during compression loading of LPBF AlSi10Mg”, Materials Science and Engineering: A, 852: 143640, (2022). [8] Krasniqi M. and Löffler F., “Comprehensive study on statistical methods for optimization of process parameters and material properties of AlSi10Mg in laser powder bed fusion”, Discover Mechanical Engineering, 3(1): 42, (2024). [9] Liu J. and Shi Y., “SiCp/AlSi10Mg composites with simultaneously enhanced tensile strength and ductility fabricated by laser powder bed fusion additive manufacturing”, Materials Science and Engineering: A, 888: 145839, (2023). [10] Mertens A., Delahaye J., Dedry O., Vertruyen B., Tchuindjang J.T. and Habraken A.M., “Microstructure and properties of SLM AlSi10Mg: Understanding the ınfluence of the local thermal history”, Procedia Manufacturing, 47: 1089-1095, (2020). [11] Miao H., Yusof F., Ab Karim M.S., Wu B., Raja S., Ibrahim M.Z., Aziz I. and Chen D., “Interfacial microstructure, element diffusion, mechanical properties and metallurgical bonding mechanism of 316L-AlSi10Mg multi-material parts fabricated by laser powder bed fusion”, Journal of Materials Research and Technology, 26: 8351–8365, (2023). [12] Pelevin I.A., Ozherelkov D.Y., Nalivaiko A.Y., Bodyakova A.I., Chernyshikhin S.V., Zotov B.O., Korshunov A.V. and Gromov A.A., “AlSi10Mg/AlN interface grain structure after laser powder bed fusion”, Metals, 12(12): 2152, (2022). [13] Raja A., Cheethirala S.R., Gupta P., Vasa N.J. and Jayaganthan R., “A review on the fatigue behaviour of AlSi10Mg alloy fabricated using laser powder bed fusion technique”, Journal of Materials Research and Technology, 17: 1013-1029, (2022). [14] Rasch M., Bartels D., Sun S. and Schmidt M., “AlSi10Mg in powder bed fusion with laser beam: An old and boring material?”, Materials, 15(16): 5651, (2022). [15] Siyambaş Y. and Turgut Y., “Experimental investigation and optimization of the effects of manufacturing parameters on geometric tolerances in additive manufacturing of AlSi10Mg alloy”, International Journal of Advanced Manufacturing Technology, 134(1–2): 415-429, (2024). [16] Toprak İ.B. and Dogdu N., “Optimization of tensile strength of AlSi10Mg material in the powder bed fusion process using the Taguchi method”, Scientific Reports, 14(1): 31172, (2024). [17] Valim D., Avila J., Sarzosa D.F.B., Justiniano C., Jardini A. and Lopes É.S.N., “Fatigue crack propagation and fracture toughness of AlSi10Mg alloy processed by powder bed fusion: effects of post-processing heat treatments”, Progress in Additive Manufacturing, 10(11): 9607-9620, (2025). [18] Wang H., He L., Zhang Q. and Yuan Y., “Influence of Ni contents on microstructure and mechanical performance of AlSi10Mg alloy by selective laser melting”, Materials, 16(13): 4679, (2023). [19] Wu Z., Wu S., Duan Y., Huang K., He W., Du D. and Dong A., “In situ X-ray tomography of fracture behaviour in low-porosity L-PBF AlSi10Mg alloy with laser shock peening”, Virtual and Physical Prototyping, 18(1): e2273955, (2023). [20] Wu Z., Wu S., Gao X., Lin Y., Xue Y. and Withers P. J., “The role of internal defects on anisotropic tensile failure of L-PBF AlSi10Mg alloys”, Scientific Reports, 13(1): 14681, (2023). [21] Xiao Y., Yang Y., Wu S., Chen J., Wang D. and Song C., “Microstructure and mechanical properties of AlSi10Mg alloy manufactured by laser powder bed fusion under nitrogen and argon atmosphere”, Acta Metallurgica Sinica (English Letters), 35(3): 486-500, (2022). [22] Zhang X., Zhang X., Liu W., Jiang A. and Long Y., “Towards understanding formation mechanism of cellular structures in laser powder bed fused AlSi10Mg”, Materials, 17(9): 2121, (2024). [23] Zhou J., Han X., Li H., Liu S. and Yi J., “Investigation of layer-by-layer laser remelting to improve surface quality, microstructure, and mechanical properties of laser powder bed fused AlSi10Mg alloy”, Materials & Design, 210: 110092, (2021). [24] Zhu X., Ma Y., Wu H., Li M. and Lu X., “In-situ tensile testing of fracture and strain in a selective laser melted AlSi10Mg alloy”, Heliyon, 10(14): e34137, (2024). [25] Zhu X., Ma Y., Wu H., Li M. and Lu X., “In-situ tensile testing of fracture and strain in a selective laser melted AlSi10Mg alloy”, Heliyon, 10(14): e34137, (2024). [26] Uludağ M., “Experimental and statistical analysis of effect of si modification and grain refinement on tensile properties of A356 alloy”, Politeknik Dergisi, 24(4): 1409-1417, (2021). [27] Kayacan M. Y. ve Yılmaz N., “DMLS eklemeli imalatta süreç ve maliyet modeli geliştirilmesi”, Politeknik Dergisi, 22(3): 763-770, (2019). [28] Karakılınç U., Yalçın B. ve Ergene B., “Toz yataklı/beslemeli eklemeli imalatta kullanılan partiküllerin uygunluk araştırması ve partikül imalat yöntemleri”, Politeknik Dergisi, 22(4): 801–810, (2019). [29] Harman M., Çetinkaya C., Yılmaz O. ve Bol N., “Comparative process parameter optimization for wire arc additive manufacturing (WAAM) of E120C-GH4 metal cored and ER120S-G solid wire”, Politeknik Dergisi, 27(5): 2013–2028, (2024). [30] Balcı A., Aycan M. F., Usta Y. ve Demir T., “Seçimli lazer ergitme ile Ti6Al4V ELI alaşımından üretilen trabeküler metal yapıların basma ve basma-kayma dayanımlarının incelenmesi”, Politeknik Dergisi, 24(3): 903–914, (2021).