The Influence of Manufacturing Parameters and Heat Treatments on the Properties of AlSi10Mg Alloy Produced Using L-PBF

AlSi10Mg has been one of the most studied and employed aluminum alloys for additive manufacturing via laser powder-bed fusion (L-PBF). The optimization of manufacturing parameters is important for reducing internal defects, including porosity and inadequate surface finishes. In addition, heat treatments, such as T6, are often applied to this alloy, but they degrade the characteristic microstructure obtained via L-PBF additive manufacturing—the fine cellular structures—which may, in turn, detrimentally affect the material’s properties. In this context, a new alternative to this treatment, direct aging (DA), has shown promise in improving the mechanical properties of AlSi10Mg parts produced via L-PBF, since it preserves the cellular microstructure, precipitating silicon-rich nanoparticles within the cells. Understanding how different temperatures and heat treatment times influence the microstructure and, consequently, the properties remains a field to be explored in order to optimize the treatment conditions and achieve better mechanical properties. Thus, the objective of this study was to evaluate the influence of manufacturing parameters and heat treatments on the microstructure and mechanical properties of AlSi10Mg alloy. The optimized manufacturing conditions were 300 W power, 800 mm/s scan speed, 30 µm layer thickness, and an argon atmosphere, which led to lower porosity and better finishing. Samples were heat-treated via DA at 150 °C and 170 °C for different times, as well as undergoing a T6 treatment (solution at 520 °C followed by aging at 150 °C and 170 °C). Initially, the aging curves show higher hardness values for the direct aging condition, compared to the T6 and as-built conditions, reaching a peak hardness of 195 HV for 6h of direct aging. In this way, it was followed with microstructural characterization, which demonstrated that DA maintained the fine cell microstructure of L-PBF and promoted the precipitation of Si nanoparticles, which certainly contributed to the increase in hardness compared to T6, which promoted a structure with coarser precipitates. DA at 170 °C for 6 h increased the tensile strength to 430 MPa, compared to the as-built condition, with a slight loss of ductility.