Additive manufacturing (AM) of high-strength Al alloys promises to enhance the performance of critical components related to various aerospace and automotive applications. The key advantage of AM is its ability to generate lightweight, robust, and complex shapes. However, the characteristics of the as-built parts may represent an obstacle to the satisfaction of the parts’ quality requirements. The current study investigates the influence of selective laser melting (SLM) process parameters on the quality of parts fabricated from different Al alloys. A design of experiment (DOE) was used to analyze relative density, porosity, surface roughness, and dimensional accuracy according to the interaction effect between the SLM process parameters. The results show a range of energy densities and SLM process parameters for AlSi10Mg and Al6061 alloys needed to achieve “optimum” values for each performance characteristic. A process map was developed for each material by combining the optimized range of SLM process parameters for each characteristic to ensure good quality of the as-built parts. This study is also aimed at reducing the amount of post-processing needed according to the optimal processing window detected.

Additive manufacturing (AM) offers customization of the microstructures and mechanical properties of fabricated components according to the material selected and process parameters applied. Selective laser melting (SLM) is a commonly-used technique for processing high strength aluminum alloys. The selection of SLM process parameters could control the microstructure of parts and their mechanical properties. However, the process parameters limit and defects obtained inside the as-built parts present obstacles to customized part production. This study investigates the influence of SLM process parameters on the quality of as-built Al6061 and AlSi10Mg parts according to the mutual connection between the microstructure characteristics and mechanical properties. The microstructure of both materials was characterized for different parts processed over a wide range of SLM process parameters. The optimized SLM parameters were investigated to eliminate internal microstructure defects. The behavior of the mechanical properties of parts was presented through regression models generated from the design of experiment (DOE) analysis for the results of hardness, ultimate tensile strength, and yield strength. A comparison between the results obtained and those reported in the literature is presented to illustrate the influence of process parameters, build environment, and powder characteristics on the quality of parts produced. The results obtained from this study could help to customize the part’s quality by satisfying their design requirements in addition to reducing as-built defects which, in turn, would reduce the amount of the post-processing needed.

Additive manufacturing is a layer based manufacturing process aimed at producing parts directly from a 3D model. This paper provides a review of key technologies for metal additive manufacturing. It focuses on the effect of important process parameters on the microstructure and mechanical properties of the resulting part. Several materials are considered including aerospace alloys such as titanium (TiAl6V4 “UNS R56400”), aluminum (AlSi10Mg “UNS A03600”), iron-and nickel-based alloys (stainless steel 316L “UNS S31603”, Inconel 718 “UNS N07718”, and Invar 36 FeNi36 “UNS K93600”).