Defects, Mechanical Properties and Surface Roughness of AlSi10Mg Alloy Parts Produced by Selective Laser Melting (SLM) Method-A Review

Metal-based additive manufacturing is a modern manufacturing process in which three-dimensional (3D) objects are fabricated by layer-by-layer melting of metallic powder or wire with an energy source. Selective laser melting (SLM) method is used in both scientific and industrial fields as it allows the production of complex and light structures. AlSi10Mg alloy is widely used in aerospace, automotive, marine and medical industries, as well as in various applications that require special designs and is one of the prominent materials in SLM research. The quality of a product produced by the SLM method requires optimization of manufacturing parameters (laser power, scanning speed, scanning distance, layer thickness) that affect the energy density required for melting. With the use of inappropriate manufacturing parameters, internal stresses arising from deformation mechanisms occur due to the process and distortion, cracking and dimensional changes occur on the part. Variables such as powder material properties, uneven distribution of powder layer, deformation during manufacturing, changes in laser beam can cause metallurgical pores. Any defects that occur in the manufacturing process have a negative effect on the mechanical properties and surface quality of the final part. In this study, the results obtained by researching the studies in the literature to produce parts with high density, high strength properties and high surface quality from AlSi10Mg alloy by selective laser melting method are presented. As a result of the research, it has been determined that energy density is more decisive on product quality. It has been determined that the ideal energy density for the least porosity in the products is in the range of 50-75 J/mm3, and the AlSi10Mg alloy parts produced by additive manufacturing show better strength properties compared to those produced by the casting method.