Investigating the Influence of AlSi10 Alloy Powder Characteristics on the Directed Energy Deposition Process

Al alloys possess excellent physical and mechanical properties, such as high strength and ductility. Recent research has actively applied additive manufacturing (AM) techniques using Al alloy powder for lightweight design to improve machine efficiency. However, the inherent physical properties of manufactured Al alloys by AM, including porosity, lack of fusion, and cracking, pose challenges in achieving defect-low additive manufacturing of high-strength Al alloys. The Al alloy powder characteristics, such as thermal conductivity and reflectance, impact the formation of defects of As-built Al alloy, like porosity and cracks, during the AM process. Controlling powder properties is therefore essential for preventing these flaws. In this study, the reflectivity, flowability, and particle size distribution of Al alloy powder produced by gas atomization were all comprehensively assessed. The microstructure and mechanical properties of the As-built Directed Energy Deposited Al alloy are subsequently analysed concerning the powder characteristics.