MATERIALS TODAY COMMUNICATIONS, sa.49, ss.1-19, 2025 (SCI-Expanded, Scopus)
Aluminum alloys offer excellent opportunities for the development of
additive manufacturing (AM) production as one of the key materials
widely used in the aerospace and automotive industries. The AlSi10Mg
alloy, which is of great interest due to its good machinability and
relatively low cost, is one of the aluminum alloys produced by laser
powder bed fusion (LPBF), the most widely used additive manufacturing
(AM) techniques. In this study, 27 different AlSi10Mg alloys were
fabricated by considering and varying the most important LPBF process
parameters affecting the physical and mechanical properties of the
produced parts and a systematic material characterization approach was
used. Among the 27 samples, the samples with the best surface roughness
characteristics were found to be samples coded S2, S11 and S20 with
100 W, 150 W and 200 W laser power, 30 µm layer thickness, 0.05 mm hatch
spacing and 750 mm/s scanning speed, respectively. On the other hand,
it was found that the optimum alloy parameters with the best physical
and mechanical properties were those used in the production of the S11
coded specimen when the microstructure, Brinell hardness, micro hardness
and density measurements of the S2, S11 and S20 specimens with the best
surface properties were evaluated. The micro hardness value of sample
S11 was found to be 141.4 ± 2.1 VHN, while the Brinell hardness value of
the sample was determined to be 127.2 ± 1.9 BHN. It was found that the
tensile strength (384.1 Mpa) of sample S11 was 95 % greater than that
(196.8 MPa) of sample S2 and that the tensile strength was approximately
40 % greater than that (279.8 MPa) of sample S20.