Effect of process parameters on the microstructure and mechanical properties of AA2024 fabricated using selective laser melting

• DOI: 10.1007/s00170-020-06346-y
• Publication Date: 2020-11-17T09:04:52Z
• Authors: Mulla Ahmet Pekok; Rossitza Setchi; Michael Ryan; Quanquan Han; Dongdong Gu
• Keywords: Selective Laser Melting; Relative density

Abstract Selective laser melting (SLM) offers significant benefits, including geometric freedom and rapid production, when compared with traditional manufacturing techniques. However, the materials available for SLM production remain limited, restricting industrial adoption of technology. The mechanical properties microstructure many aluminium alloys have not been fully explored, as their manufacturability using is extremely challenging. This study investigates effect power, hatch spacing scanning speed on microstructural as-fabricated 2024 alloy (AA2024) manufactured SLM. results reveal that almost crack-free structures high relative density (99.9%) Archimedes (99.7%) achieved. It shown low energy (ED) levels, large cracks porosities are a major problem, owing to incomplete fusion; however, small gas pores prevalent at high-energy densities due dissolved particles in melt pool. An inversely proportional relationship between ED microhardness has also observed. Lower decreases pool size temperature gradients but increases cooling rate, creating fine-grained microstructure, which restricts dislocation movement, therefore increasing microhardness. highest (116 HV 0.2 ), was obtained from one lowest EDs used (100 J/mm 3 45% higher than as-cast AA2024-0, 17% lower wrought AA2024-T6 alloy.