Effect of nAl₂O₃ on the part density and microstructure during the laser-based powder bed fusion of AlSi₁₀Mg composite

Abstract

Purpose

In recent years, additive manufacturing techniques have attracted much research attention because of their ability to fabricate customised parts with complex geometry. The range of composites suitable for laser-based powder bed fusion technique is limited, and has not been investigated yet. This paper aims to study the fabrication of AlSi₁₀Mg reinforced with nAl₂O₃ using the laser-based powder bed fusion technique.

Design/methodology/approach

An experimental approach was used to investigate the densification of AlSi₁₀Mg–nAl₂O₃ composites using laser-based powder bed fusion technique. Optimisation of the porosity was performed, and microstructure evolution was evaluated.

Findings

In this study, laser volumetric energy density (approximately 109 J/mm³) was found to be required for the fabrication of AlSi₁₀Mg–nAl₂O₃ composites with a relative volumetric density approximating 99%. The use of laser volumetric energy density resulted in larger grains. Columnar grain structure was observed via the use of electron backscatter diffraction mapping.

Originality/value

This paper examines the processing of new aluminium composite material suitable for the fabrication via the laser-based powder bed fusion technique.

Citation

Du, Z., Chen, H.-C., Tan, M.J., Bi, G. and Chua, C.K. (2020), "Effect of nAl₂O₃ on the part density and microstructure during the laser-based powder bed fusion of AlSi₁₀Mg composite", Rapid Prototyping Journal, Vol. 26 No. 4, pp. 727-735. https://doi.org/10.1108/RPJ-05-2019-0136