Fabrication and mechanical properties of Al–Si-based alloys by selective laser melting process

Aluminium (Al)-based alloys have attracted as promising materials for structural applications using metal 3D printing due to their excellent specific mechanical strength, formability, and durability. In this study, highly flowable coarse AlSi10Mg powders with average diameter of 65 µm were prepared and then they were additively manufactured by using the selective laser melting (SLM) process. The relative densities exceeding 99% were consistently obtained from the samples fabricated at the scan speed of 1000–2000 mm·s⁻¹ in the range of laser power from 350 to 390 W. The tensile strengths and elongation of all the samples were characterised. Furthermore, Al alloy processed by coarse AlSi10Mg powders does not show a big change in strength values compared to those fabricated by fine AlSi10Mg powders with 45 µm in diameter. Thus, these results clearly show that the developed coarse AlSi10Mg powders can be effectively utilised for the SLM process.