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Evaluation of structural and mechanical properties of high strength aluminum alloy components fabricated using laser powder bed fusion process

The structural and mechanical analyses were performed on an aluminum alloy (AlSi10Mg) fabricated using a laser powder bed fusion process where the laser power and the scan speed were varied. An x-ray diffraction analysis was performed on the specimens and Mg2Si clusters were detected. A heat-affected zone and fine and coarse grain regions were observed using optical microscopy and a field emission scanning electron microscope. By increasing the laser power at a fixed scan speed, the microstructure becomes finer, which was further confirmed by measuring the size of grains. By increasing the scan speed at a fixed laser power, the microstructure was found to be coarser. Relative density, microhardness, and surface roughness tests were performed on specimens to study the mechanical properties. An increase in laser power improved the relative density and microhardness wherein the surface roughness reduced. An increase in scan speed resulted in a decrease in relative density and microhardness of the samples, which increased the surface roughness.