Influence of Laser-Based Powder Bed Fusion of Metals Process Parameters on the Formation of Defects in Al-Zn-Mg-Cu Alloy Using Path Analysis

High-strength aluminium alloys are prone to porosity and cracking during laser-based powder bed fusion of metals (PBF-LB/M) due to the complex solidification behaviour, thus limiting the preparation of high-quality aluminium alloys. In order to effectively reduce the defect formation, this study investigated the influence mechanism of different process parameters on the formation of porosity and cracks in Al-Zn-Mg-Cu alloys in the PBF-LB/M process by combining experimental and numerical simulation. The degree of influence of the process parameters on the temperature field and the temperature field on the defect formation was also quantified using path analysis. The results show that modulation of the process parameters can effectively reduce the formation of cracks and pores, although it is difficult to eliminate them. The melt pool temperature has a significant effect on the formation of porosity, and the temperature gradient has a significant effect on the formation of cracks. The degree of influence of laser power on the melt pool temperature and temperature gradient was greater than that of scanning speed, with values of 0.980 and 0.989, respectively. Therefore, the priority of modulating the laser power is higher than that of scanning speed in order to reduce the formation of defects more effectively.