Modeling and Optimization of Process Parameters for Laser Powder Bed Fusion of AlSi10Mg Alloy

Direct Metal Laser Sintering (DMLS) is a laser powder bed fusion process, grabs the attention of industries to make metal components directly from the metal powders. However, the quality of the build component depends on the sintering depth as well as sintering mechanism which are directly influenced by process parameters. Proper selection of process parameters to build the component is the key to the success of the DMLS process at commercial level. A common solution to make a quality component is to fuse the powder layers with maximum layered thickness, which can be achieved with appropriate selection of process parameters. In the present research, finite element simulations have been carried out to measure the sintering depth at different process parameters such as laser power, scan speed, porosity percentage, laser spot size, and powder bed thickness. Based on the predicted temperature field and sintering depth, an optimization model was developed by using response surface methodology with an aim to optimize the process parameters that improve the printing quality. The accuracy of the model was confirmed by using analysis of variance. From the optimization model, it is found that maximum sintering depth of 3 mm achieved with a laser power of 162 W, a scan speed of 156 mm/s, the percentage of porosity of 20%, a laser spot size of 0.2 mm, and the powder layer thickness of 1 mm respectively. This optimized model will help to design and control the process parameters for building quality components.