Study of the Surface and Dimensional Quality of the AlSi10Mg Thin-Wall Components Manufactured by Selective Laser Melting
Abstract
:1. Introduction
2. Experimental Method and Procedure
2.1. Equipment and Material
2.2. Powder Characterization
2.3. Response Surface Methodology in Combination with Design of Experiment (DOE)
- Investigation of SLM process parameters’ influence upon the surface and dimensional quality of AlSi10Mg specimens;
- To study the impact of variations of wall thickness and process parameters on surface roughness and the dimensional accuracy of the specimens;
- To determine the effect of post-processing techniques (i.e., sand blasting and polishing) on the surface and dimensional quality of the specimens;
- By using optimization techniques, to define a set of optimal process parameters against surface roughness and dimensional accuracy.
DOE by Using Minitab 17
3. Experimental Results and Analysis
3.1. Experimental Approach
3.2. Surface Roughness of as-Built Samples
3.2.1. Surface Roughness of Sand-Blasted Samples
3.2.2. Dimensional Accuracy of the Samples
3.3. Surface Roughness
Regression Equation
3.4. Dimensional Accuracy
3.4.1. Length of the Samples
Regression Equation
3.4.2. Height of the Samples
Regression Equation
3.5. Selection of Optimum Process Parameters
4. Conclusions
- (1)
- With p-value and F-test value, wall thickness proved to have the most substantial influence on the length of the specimens in terms of dimensional accuracy. Length accuracy improved greatly when wall thickness varied from 1.0 to 2.0 mm. A further improvement in accuracy was observed when wall thickness varied from 2.0 to 3.0 mm;
- (2)
- The response estimation model developed for length of the specimens was significant and yielded an R2 of 82.14%. This means that the developed model fits more than 80% of the response data;
- (3)
- The values for SR, length, and height were predicted on the basis of respective regression equations developed with regression analysis of the responses. The SR, length, and height were predicted accurately with minimum error of 0.005%, 0.0%, and 0.002%, respectively, as compared to experimental values;
- (4)
- The most precise value for height was achieved at a wall thickness of 1.0 mm, laser power of 320 W, scan speed of 730 mm/s, and hatch distance of 105 µm;
- (5)
- The most accurate value for length was attained at a wall thickness of 3.0 mm, laser power of 350 W, scan speed of 730 mm/s, and hatch distance of 130 µm;
- (6)
- Multi-objective optimization methods can be used to optimize different process parameters of the SLM process simultaneously;
- (7)
- More statistical methods, such as the Taguchi method, artificial neural networks, fuzzy logic, genetic algorithms, and grey relational analysis, can be applied to analyze results.
Author Contributions
Funding
Conflicts of Interest
Abbreviations
Nomenclature | |
ASTM | American Society for Testing and Materials |
AM | Additive Manufacturing |
SLM | Selective Laser Melting |
EBM | Electron Beam Melting |
DED | Directed Energy Deposition |
BBD | Box–Behnken Design |
RSM | Response Surface Methodology |
SEM | Scanning Electron Microscope |
3D | Three Dimensional |
CAD | Computer-Aided Design |
DOE | Design of Experiment |
CCD | Central Composite Design |
BBD | Box–Behnken Design |
EIMSE | Expected Integrated Mean Squared Error |
SEM | Scanning Electron Microscope |
SR | Surface Roughness |
WT | Wall Thickness |
Auto Fab | Auto Fabrication |
LP | Laser Power |
SS | Scan Speed |
HD | Hatch Distance |
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ELEMENT | Si | Fe | Cu | Mn | Mg | Zn | Ti | Al |
---|---|---|---|---|---|---|---|---|
Weight % | 9–11 | ≤0.55 | ≤0.05 | ≤0.45 | 0.2–0.45 | ≤0.1 | ≤0.15 | Balance |
Parameters | Unit | Level | ||
---|---|---|---|---|
−1 | 0 | 1 | ||
Wall Thickness | mm | 1.0 | 2.0 | 3.0 |
Laser Power | Watt | 320 | 350 | 380 |
Scan Speed | mm/s | 730 | 900 | 1070 |
Hatch Distance | µm | 80 | 105 | 130 |
Run Order | Wall Thickness (mm) | Laser Power (Watt) | Scan Speed (mm/s) | Hatch Distance (µm) |
---|---|---|---|---|
1 | 1 | 320 | 900 | 105 |
2 | 3 | 320 | 900 | 105 |
3 | 1 | 380 | 900 | 105 |
4 | 3 | 380 | 900 | 105 |
5 | 2 | 350 | 730 | 80 |
6 | 2 | 350 | 1070 | 80 |
7 | 2 | 350 | 730 | 130 |
8 | 2 | 350 | 1070 | 130 |
9 | 1 | 350 | 900 | 80 |
10 | 3 | 350 | 900 | 80 |
11 | 1 | 350 | 900 | 130 |
12 | 3 | 350 | 900 | 130 |
13 | 2 | 320 | 730 | 105 |
14 | 2 | 380 | 730 | 105 |
15 | 2 | 320 | 1070 | 105 |
16 | 2 | 380 | 1070 | 105 |
17 | 1 | 350 | 730 | 105 |
18 | 3 | 350 | 730 | 105 |
19 | 1 | 350 | 1070 | 105 |
20 | 3 | 350 | 1070 | 105 |
21 | 2 | 320 | 900 | 80 |
22 | 2 | 380 | 900 | 80 |
23 | 2 | 320 | 900 | 130 |
24 | 2 | 380 | 900 | 130 |
25 | 2 | 350 | 900 | 105 |
26 | 2 | 350 | 900 | 105 |
27 | 2 | 350 | 900 | 105 |
Run Order | WT (mm) | LP (W) | SS (mm/s) | HD (µm) | SR (µm) |
---|---|---|---|---|---|
1 | 1 | 320 | 900 | 105 | 11.575 |
2 | 3 | 320 | 900 | 105 | 8.985 |
3 | 1 | 380 | 900 | 105 | 8.873 |
4 | 3 | 380 | 900 | 105 | 12.210 |
5 | 2 | 350 | 730 | 80 | 12.156 |
6 | 2 | 350 | 1070 | 80 | 10.391 |
7 | 2 | 350 | 730 | 130 | 13.111 |
8 | 2 | 350 | 1070 | 130 | 9.563 |
9 | 1 | 350 | 900 | 80 | 11.012 |
10 | 3 | 350 | 900 | 80 | 11.610 |
11 | 1 | 350 | 900 | 130 | 13.816 |
12 | 3 | 350 | 900 | 130 | 10.146 |
13 | 2 | 320 | 730 | 105 | 9.538 |
14 | 2 | 380 | 730 | 105 | 9.993 |
15 | 2 | 320 | 1070 | 105 | 10.159 |
16 | 2 | 380 | 1070 | 105 | 10.477 |
17 | 1 | 350 | 730 | 105 | 10.240 |
18 | 3 | 350 | 730 | 105 | 12.682 |
19 | 1 | 350 | 1070 | 105 | 10.108 |
20 | 3 | 350 | 1070 | 105 | 9.587 |
21 | 2 | 320 | 900 | 80 | 11.086 |
22 | 2 | 380 | 900 | 80 | 10.945 |
23 | 2 | 320 | 900 | 130 | 11.818 |
24 | 2 | 380 | 900 | 130 | 9.182 |
25 | 2 | 350 | 900 | 105 | 9.727 |
26 | 2 | 350 | 900 | 105 | 10.869 |
27 | 2 | 350 | 900 | 105 | 10.253 |
Run Order | WT (mm) | LP (W) | SS (mm/s) | HD (µm) | SR (µm) |
---|---|---|---|---|---|
1 | 1 | 320 | 900 | 105 | 6.355 |
2 | 3 | 320 | 900 | 105 | 6.590 |
3 | 1 | 380 | 900 | 105 | 6.748 |
4 | 3 | 380 | 900 | 105 | 8.040 |
5 | 2 | 350 | 730 | 80 | 5.557 |
6 | 2 | 350 | 1070 | 80 | 5.337 |
7 | 2 | 350 | 730 | 130 | 5.442 |
8 | 2 | 350 | 1070 | 130 | 5.620 |
9 | 1 | 350 | 900 | 80 | 7.622 |
10 | 3 | 350 | 900 | 80 | 6.290 |
11 | 1 | 350 | 900 | 130 | 13.270 |
12 | 3 | 350 | 900 | 130 | 6.450 |
13 | 2 | 320 | 730 | 105 | 4.750 |
14 | 2 | 380 | 730 | 105 | 3.770 |
15 | 2 | 320 | 1070 | 105 | 4.200 |
16 | 2 | 380 | 1070 | 105 | 4.870 |
17 | 1 | 350 | 730 | 105 | 6.049 |
18 | 3 | 350 | 730 | 105 | 7.380 |
19 | 1 | 350 | 1070 | 105 | 5.947 |
20 | 3 | 350 | 1070 | 105 | 5.500 |
21 | 2 | 320 | 900 | 80 | 5.890 |
22 | 2 | 380 | 900 | 80 | 4.920 |
23 | 2 | 320 | 900 | 130 | 6.080 |
24 | 2 | 380 | 900 | 130 | 4.650 |
25 | 2 | 350 | 900 | 105 | 5.500 |
26 | 2 | 350 | 900 | 105 | 5.250 |
27 | 2 | 350 | 900 | 105 | 5.600 |
Run Ord. | WT (mm) | LP (W) | SS (mm/s) | HD (µm) | Length (mm) | Height (mm) |
---|---|---|---|---|---|---|
1 | 1 | 320 | 900 | 105 | 54.818 | 12.025 |
2 | 3 | 320 | 900 | 105 | 54.920 | 12.030 |
3 | 1 | 380 | 900 | 105 | 54.805 | 12.068 |
4 | 3 | 380 | 900 | 105 | 54.933 | 12.050 |
5 | 2 | 350 | 730 | 80 | 54.958 | 12.020 |
6 | 2 | 350 | 1070 | 80 | 54.943 | 12.045 |
7 | 2 | 350 | 730 | 130 | 54.953 | 12.018 |
8 | 2 | 350 | 1070 | 130 | 54.920 | 12.055 |
9 | 1 | 350 | 900 | 80 | 54.795 | 12.073 |
10 | 3 | 350 | 900 | 80 | 54.940 | 12.060 |
11 | 1 | 350 | 900 | 130 | 54.895 | 12.033 |
12 | 3 | 350 | 900 | 130 | 54.965 | 12.070 |
13 | 2 | 320 | 730 | 105 | 54.883 | 12.025 |
14 | 2 | 380 | 730 | 105 | 54.905 | 12.055 |
15 | 2 | 320 | 1070 | 105 | 54.900 | 12.025 |
16 | 2 | 380 | 1070 | 105 | 54.920 | 12.035 |
17 | 1 | 350 | 730 | 105 | 54.848 | 11.998 |
18 | 3 | 350 | 730 | 105 | 54.950 | 12.010 |
19 | 1 | 350 | 1070 | 105 | 54.883 | 12.008 |
20 | 3 | 350 | 1070 | 105 | 54.888 | 12.020 |
21 | 2 | 320 | 900 | 80 | 54.920 | 12.028 |
22 | 2 | 380 | 900 | 80 | 54.935 | 12.060 |
23 | 2 | 320 | 900 | 130 | 54.888 | 12.078 |
24 | 2 | 380 | 900 | 130 | 54.918 | 12.073 |
25 | 2 | 350 | 900 | 105 | 54.913 | 12.065 |
26 | 2 | 350 | 900 | 105 | 54.983 | 12.043 |
27 | 2 | 350 | 900 | 105 | 54.963 | 12.038 |
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Waqas, M.; He, D.; Elahi, H.; Riaz, S.; Eugeni, M.; Gaudenzi, P. Study of the Surface and Dimensional Quality of the AlSi10Mg Thin-Wall Components Manufactured by Selective Laser Melting. J. Compos. Sci. 2021, 5, 126. https://0-doi-org.brum.beds.ac.uk/10.3390/jcs5050126
Waqas M, He D, Elahi H, Riaz S, Eugeni M, Gaudenzi P. Study of the Surface and Dimensional Quality of the AlSi10Mg Thin-Wall Components Manufactured by Selective Laser Melting. Journal of Composites Science. 2021; 5(5):126. https://0-doi-org.brum.beds.ac.uk/10.3390/jcs5050126
Chicago/Turabian StyleWaqas, Muhammad, Dingyong He, Hassan Elahi, Saleem Riaz, Marco Eugeni, and Paolo Gaudenzi. 2021. "Study of the Surface and Dimensional Quality of the AlSi10Mg Thin-Wall Components Manufactured by Selective Laser Melting" Journal of Composites Science 5, no. 5: 126. https://0-doi-org.brum.beds.ac.uk/10.3390/jcs5050126