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- A Parametric Study on the L-PBF Process of an AlSi10Mg Alloy for High-Speed Productivity of Automotive Prototype Parts
- Yeonha Chang, Hyomoon Joo, Wanghyun Yong, Yeongcheol Jo, Seongjin Kim, Hanjae Kim, Yeon Woo Kim, Kyung Tae Kim, Jeong Min Park
- J Powder Mater. 2024;31(5):390-398. Published online October 31, 2024
- DOI: https://doi.org/10.4150/jpm.2024.00325
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Abstract
PDF - The AlSi10Mg alloy has garnered significant attention for its application in laser powder bed fusion (L-PBF), due to its lightweight properties and good printability using L-PBF. However, the low production speed of the L-PBF process is the main bottleneck in the industrial commercialization of L-PBF AlSi10Mg alloy parts. Furthermore, while L-PBF AlSi10Mg alloy exhibits excellent mechanical properties, the properties are often over-specified compared to the target properties of parts traditionally fabricated by casting. To accelerate production speed in L-PBF, this study investigated the effects of process parameters on the build rate and mechanical properties of the AlSi10Mg alloy. Guidelines are proposed for high-speed additive manufacturing of the AlSi10Mg alloy for use in automotive parts. The results show a significant increase in the build rate, exceeding the conventional build rate by a factor of 3.6 times or more, while the L-PBF AlSi10Mg alloy met the specifications for automotive prototype parts. This strategy can be expected to offer significant cost advantages while maintaining acceptable mechanical properties of topology-optimized parts used in the automobile industry.
- Data-driven Approach to Explore the Contribution of Process Parameters for Laser Powder Bed Fusion of a Ti-6Al-4V Alloy
- Jeong Min Park, Jaimyun Jung, Seungyeon Lee, Haeum Park, Yeon Woo Kim, Ji-Hun Yu
- J Powder Mater. 2024;31(2):137-145. Published online April 30, 2024
- DOI: https://doi.org/10.4150/jpm.2024.00038
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Abstract
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- In order to predict the process window of laser powder bed fusion (LPBF) for printing metallic components, the calculation of volumetric energy density (VED) has been widely calculated for controlling process parameters. However, because it is assumed that the process parameters contribute equally to heat input, the VED still has limitation for predicting the process window of LPBF-processed materials. In this study, an explainable machine learning (xML) approach was adopted to predict and understand the contribution of each process parameter to defect evolution in Ti alloys in the LPBF process. Various ML models were trained, and the Shapley additive explanation method was adopted to quantify the importance of each process parameter. This study can offer effective guidelines for fine-tuning process parameters to fabricate high-quality products using LPBF.
- Analysis of the Effects of Process Variables and Alloy Composition on the Relative density and Mechanical Properties of 3D Printed Aluminum Alloys
- Suwon Park, Jiyoon Yeo, Songyun Han, Hyunjoo Choi
- J Powder Mater. 2023;30(3):223-232. Published online June 1, 2023
- DOI: https://doi.org/10.4150/KPMI.2023.30.3.223
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Abstract
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Metal additive manufacturing (AM) has transformed conventional manufacturing processes by offering unprecedented opportunities for design innovation, reduced lead times, and cost-effective production. Aluminum alloy, a material used in metal 3D printing, is a representative lightweight structural material known for its high specific strength and corrosion resistance. Consequently, there is an increasing demand for 3D printed aluminum alloy components across industries, including aerospace, transportation, and consumer goods. To meet this demand, research on alloys and process conditions that satisfy the specific requirement of each industry is necessary. However, 3D printing processes exhibit different behaviors of alloy elements owing to rapid thermal dynamics, making it challenging to predict the microstructure and properties. In this study, we gathered published data on the relationship between alloy composition, processing conditions, and properties. Furthermore, we conducted a sensitivity analysis on the effects of the process variables on the density and hardness of aluminum alloys used in additive manufacturing.
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- Effect of Heat Treatment on Microstructure and Mechanical Properties of Al–Zn–Mg–Cu–Si Sintered Alloys with and Without High-energy Ball Milling
Junho Lee, Seonghyun Park, Sang-Hwa Lee, Seung Bae Son, Seok-Jae Lee, Jae-Gil Jung
journal of Korean Powder Metallurgy Institute.2023; 30(6): 470. CrossRef
- Effect of Heat Treatment on Microstructure and Mechanical Properties of Al–Zn–Mg–Cu–Si Sintered Alloys with and Without High-energy Ball Milling
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