A1 Refereed original research article in a scientific journal
Anisotropy of additively manufactured AlSi10Mg: threads and surface integrity
Authors: Ullah R, Akmal JS, Laakso SVA, Niemi E
Publisher: SPRINGER LONDON LTD
Publication year: 2020
Journal: International Journal of Advanced Manufacturing Technology
Journal name in source: INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
Journal acronym: INT J ADV MANUF TECH
Volume: 107
Issue: 9-10
First page : 3645
Last page: 3662
Number of pages: 18
ISSN: 0268-3768
DOI: https://doi.org/10.1007/s00170-020-05243-8(external)
Abstract
Implementing additive manufacturing in an industry, particularly for critical applications of lightweight aluminum (AlSi10Mg), requires part properties that are both accurate and precise to conform to the intent of a robust design. In this experimental study, the objective was to evaluate anisotropy in part properties (i.e., flatness, surface roughness, surface porosity, surface hardness, pre-hole shrinkage, drilling thrust force, and thread-stripping force) when the part orientation (i.e., print inclination and recoater angle) was independently changed. This study developed and investigated an innovative procedure for determining anisotropy in part properties. The part properties were evaluated by designing specific features on a tailor-made flat plate. The replicas of the aluminum plate were additively manufactured at varying orientations using two commercial EOS parameter sets for the laser-based powder bed fusion technique. Conventional measurement equipment was used to analyze all the part properties, except the thread-stripping force, which was measured using a custom-made setup. All the part properties indicated a considerable degree of anisotropy, excluding the drilling thrust force. The printing parameters dictate the significance of the anisotropy. The anisotropy in flatness and pre-hole shrinkage decreases with an increased substrate temperature and a decrease in energy input and thermal gradient. The presence of surface overlapping contours in the scan strategy and an increased energy input can reduce anisotropy in surface roughness and hardness. No significant anisotropy was detected when the recoater angle was changed. This study helps designers establish and substantiate design for additive manufacturing that is within the limits of appropriate anisotropy for a robust design.
Implementing additive manufacturing in an industry, particularly for critical applications of lightweight aluminum (AlSi10Mg), requires part properties that are both accurate and precise to conform to the intent of a robust design. In this experimental study, the objective was to evaluate anisotropy in part properties (i.e., flatness, surface roughness, surface porosity, surface hardness, pre-hole shrinkage, drilling thrust force, and thread-stripping force) when the part orientation (i.e., print inclination and recoater angle) was independently changed. This study developed and investigated an innovative procedure for determining anisotropy in part properties. The part properties were evaluated by designing specific features on a tailor-made flat plate. The replicas of the aluminum plate were additively manufactured at varying orientations using two commercial EOS parameter sets for the laser-based powder bed fusion technique. Conventional measurement equipment was used to analyze all the part properties, except the thread-stripping force, which was measured using a custom-made setup. All the part properties indicated a considerable degree of anisotropy, excluding the drilling thrust force. The printing parameters dictate the significance of the anisotropy. The anisotropy in flatness and pre-hole shrinkage decreases with an increased substrate temperature and a decrease in energy input and thermal gradient. The presence of surface overlapping contours in the scan strategy and an increased energy input can reduce anisotropy in surface roughness and hardness. No significant anisotropy was detected when the recoater angle was changed. This study helps designers establish and substantiate design for additive manufacturing that is within the limits of appropriate anisotropy for a robust design.
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