Procedure for Commissioning a Metallic Powder Bed Fusion Printing Technology for the Fabrication of a Light Aerospace Mechanical Assembly

This document outlines the quality standards, experimental configurations, and precise workflows utilized to execute a metallic powder bed fusion process for creating aerospace test pieces. Using AlSi10Mg alloy, validation specimens were produced on a TRUMPF TruPrint 2000 machine according to a dedicated commissioning strategy. Metallographic evaluations targeted grain dimensions, morphology, boundaries, and phase compositions like precipitates or carbides. Findings showed scattered precipitates averaging 4 µm across the cross-sections. Subsequent X-ray microtomography (XCT) assessed porosity levels plus defect geometry and placement, offering comprehensive data on specific inclusions alongside broader statistics. XCT detected internal pore sizes ranging from 0.02 to 0.9 mm and rare clusters of high-density particles with a diameter of approximately 0.03 mm. Tensile evaluations of two batches showed a 72 GPa longitudinal elasticity modulus, 240 MPa offset yield strength, 350 MPa ultimate tensile strength, and 7% failure elongation. These positive results finalized a successful commissioning phase, enabling the subsequent design of lightweight aerospace mechanical assemblies.