A detailed study on optimizing DMLS process parameters to enhance AlSi10Mg metal component properties

Abstract This study investigates the effects of laser power, scan speed, and hatch distance on the features of aluminium specimens produced using direct metal laser sintering (DMLS). By systematically varying these parameters, we identified optimal combinations for producing high-quality metal components. Our findings were validated through reproducible printing processes. Analysis of variance (ANOVA) and grey relational analysis (GRA) were employed to optimize the production parameters further. We found a significant trade-off between laser power, tensile strength, and fatigue resistance, with laser power having the most substantial impact on mechanical properties, microstructure, and surface roughness. Statistical analysis confirmed that higher laser power improves mechanical characteristics but may increase surface roughness. These insights are crucial for enhancing the efficiency and quality of DMLS-produced metal components.