Fabrication and Characterization of AlSi10Mg Alloy Using Laser Directed Energy Deposition

In this study, we attempted to fabricate specimens with AlSi10Mg alloy powder by using laser directed energy deposition (DED-LB). Single- and multi-beads (plane) were fabricated with varying DED-LB process conditions, and the bead shapes were measured. Notably, the shapes significantly changed depending on the process conditions. Based on the results, appropriate DED-LB process conditions were selected, under which a smooth plane could be fabricated. Fabricating under the appropriate process conditions, AlSi10Mg DED-LB specimens with a high relative density of greater than 99.8% were obtained. Then, DED-LB specimens with a block shape were fabricated using different scanning patterns (XX and XY patterns) under the appropriate process conditions, and their microstructures and mechanical properties were investigated. The density and microstructural morphology of the DED-LB specimens changed depending on the scanning patterns. The DED-LB specimens fabricated using the XY scanning pattern, in which the scanning direction was changed for each layer, exhibited superior strength and ductility. This was attributed to the differences in relative density and microstructures of the specimens.