Due to high production costs and a limited reproducibility of quality, the high potential of laser powder bed fusion (LPBF)
has not been fully exploited yet. In fact, internal defects can have a detrimental effect on the fatigue behaviour and cause
final component failure. Therefore, process-induced defects must be localized and evaluated at a higher level of detail. The
present study deals with the correlation amongst pores and LPBF process parameters in AlSi10Mg components. Computed
tomography (CT) allows an extensive examination of internal defects. Within this work, a total number of 2,939,830 pores
detected in 96 cylindrical samples were analysed using CT. The formation of pores can be adjusted by varying the modified
volume energy density, for example, by using various laser scanning speeds. Furthermore, the effect of powder preparation
scan strategies (pre-heating and pre-sintering) on the formation of different pore types as well as the general reproducibility
was examined. For instance, the shielding gas flow, contaminated protective windows of the lasers as well as prior powder
preparation influence the formation of pores. Using prior laser powder preparation reduced the total number of pores at high
scanning speeds up to 45%. When the scanning speed is increased, the number of spherical pores decreases and large and
irregularly shaped pores appear. Interestingly, only the pre-heating process resulted in a reduced formation of spherical pores
at low scanning speeds (1000 mm/s).
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Due to high production costs and a limited reproducibility of quality, the high potential of laser powder bed fusion (LPBF)
has not been fully exploited yet. In fact, internal defects can have a detrimental effect on the fatigue behaviour and cause
final component failure. Therefore, process-induced defects must be localized and evaluated at a higher level of detail. The
present study deals with the correlation amongst pores and LPBF process parameters in AlSi10Mg components. Computed
tomogr...
»
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