Page 110 - MSAM-4-2

Materials Science in Additive Manufacturing Impact of cell angle on AlSi10Mg structures

were fabricated using LPBF according to the design the reconstructed models and the theoretical designs falls
models. The Dodeca and Octa structures are presented within a narrow range of 1.3% – 3.45% (Figure 5C), further
with designed 80% and 90% porosities labeled as P80 and confirming high accuracy in the LPBF manufacturing
P90, respectively. Specifically, Figure 4A and B illustrate the process. Furthermore, Figure 5C and D provide a
Dodeca-A, Dodeca-B, and Dodeca-C structures with 80% comparative analysis of the theoretical and actual volumes
and 90% porosity, whereas Figure 4C and D display the of the structures, demonstrating that the deviation in
Octa-A and Octa-B structures with the designed porosity volume remains within 4%. This minimal deviation
levels, accordingly. It can be observed that the LPBF-built indicates a good consistency between the reconstructed
AlSi10Mg structures exhibit a high dimensional resolution models and the theoretical designs, suggesting that the
finish under the optimized process parameters, which manufacturing process effectively replicates the intended
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aligns with the high precision of the LPBF process. geometries. As a result, the impact of manufacturing
Three identical structures were produced and tested in variations on the mechanical properties of the LPBF-
repeated experiments to ensure repeatability. However, built Dodeca and Octa AlSi10Mg structures is considered
slight deviations from macro to micro levels between the negligible in this study. This consistency provides a solid
theoretical design dimensions and the actual manufactured foundation for analyzing the impact behavior of different
samples can occur due to residual powder adhesion and porous structures, enabling accurate assessments of their
localized over-melting in certain overhang regions during performance under dynamic loading conditions.
the LPBF process. Therefore, further characterization of Figure 6A presents SEM images of the sample surface,
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the micro-level differences is needed to assess the effects of revealing a significant number of particles adhered to the
LPBF manufacturing parameters on dimensional accuracy porous structure. These observations are consistent with
and to minimize the impact of these differences on the findings reported by Al-Ketan et al. In addition, Figure 6B
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evaluation of dynamic performance. illustrates the melt pool tracks and morphologies, revealing
Figure 5A and B present a comparison of the X-CT very few irregular pore defects in the LPBF-fabricated
reconstructed models of the Octa-A structures fabricated AlSi10Mg samples. Measurement results indicate that the
from LPBF-built AlSi10Mg alloy, featuring porosities of densification rate of the sample is 99.4% (i.e., high relative
80% and 90% (i.e., Octa-A P80 and Octa-A P90), with density). The schematic laser scanning path during the
their corresponding theoretical design models. The melting process is illustrated in Figure 6C, with an angle
comparison reveals that the dimensional disparity between increment of 67° for each layer, which aligns with Figure 6B.

A B

C D

Figure 4. Dodeca and Octa AlSi10Mg structures with 80% and 90% porosity were prepared through laser powder bed fusion according to the designed
models. (A) Dodeca-A, Dodeca-B, and Dodeca-C with 80% porosity, (B) Dodeca-A, Dodeca-B, and Dodeca-C with 90% porosity, (C) Octa-A and Octa-B
with 80% porosity, and (D) Octa-A and Octa-B with 90% porosity
Abbreviations: Dodeca: Dodecahedral; Octa: Octahedral

Volume 4 Issue 2 (2025) 6 doi: 10.36922/MSAM025130019