Page 23 - MSAM-3-3

Materials Science in Additive Manufacturing Defects in additively fabricated Al6061

Table 2. Process parameters, energy density, and measured relative density for pores and cracks of set 2
Laser power, Scan velocity, Hatch distance, Energy density, Porosity Crack
P (W) v (mm/s) h (mm) E (J/mm ) density, density, ε
3
s rel
ϕ
rel
190 100 0.1 380.00 3.35 0.7
200 100 0.1 400.00 0.6 0.23
210 100 0.1 420.00 1.29 0.56
220 100 0.1 440.00 1.37 0.83
247.5 400 0.1 123.75 3.52 1.73
261.25 400 0.1 130.63 1.39 1.45
275 400 0.1 137.50 0.7 2.01
288.75 400 0.1 144.38 0.9 1.88
302.5 400 0.1 151.25 3.36 1.48
450 1496 0.1 60.16 0.64 2.59
450 1683 0.1 53.48 0.65 2.6
450 1870 0.1 48.13 0.42 2.33
200 85 0.1 470.59 1.7 0.33
200 90 0.1 444.44 1.75 0.37
200 100 0.1 400.00 2.8 0.66
200 110 0.1 363.64 2.11 0.98
200 120 0.1 333.33 2.73 0.94
275 360 0.1 152.78 3.19 1.43
275 380 0.1 144.74 3.61 1.65
275 400 0.1 137.50 0.7 2.01
275 420 0.1 130.95 0.98 2.68
360 1496 0.1 48.13 0.66 3.92
400 1400 0.1 57.14 0.57 2.32
405 1496 0.1 54.14 1.2 4.7
405 1870 0.1 43.32 1.13 2.78
A B C

Figure 1. Defect quantification: (A) actual image, (B) background removal, and (C) processed for cracks (red) and pores (green). Scale bar: 1 mm
counting of the defects. The selection of 10 is empirical employed. The removal of pores is contingent upon
and matches the continuity of cracks. These pixels are their grayscale value falling below a designated
subsequently assigned a value of 255, rendering them grayscale color value, typically set at 110, and the
as white background elements (Figure 1B). satisfaction of specific conditions regarding the
(ii) Defect detection: Following background removal, number of neighboring pixels that meet this grayscale
two distinct filters to identify cracks and pores were criterion. Meanwhile, cracks are discriminated from

Volume 3 Issue 3 (2024) 5 doi: 10.36922/msam.3652