Abstract Scope |
Additive Manufacturing (AM) offers a new paradigm in design of alloys with complex microstructure. Integrating materials technology, materials design and manufacturing innovation is a new frontier of AM development. The objective is to develop 1) meltpool engineering with process and void maps to characterize thermal history and porosity of AlSi10Mg, and 2) grain boundary engineering of alloy composition and grain size for different AM process parameters. AM parts 3D-printed by Laser Power Bed Fusion (LPBF) need to be qualified for (i) defects (micro, macro), (ii) net-shape warpage, (iii) high residual stresses, (iv) surface roughness, (v) voids, (vi) anisotropic microstructures due to variable cooling rates, and (vii) scatter in mechanical properties. AM defects (e.g., unfused powder, balling, humping, and keyholing) are affected by variations in power and speed as well as hatch spacing. Predictions for i) voids and density maps for AlSi10Mg, and ii) stress-strain curves are compared with experimental data. |