Process Optimization for Up-Facing Surface Finish of AlSi10Mg Alloy Produced by Laser Powder Bed Fusion
Abstract
:1. Introduction
2. Experimental Procedures
2.1. Materials and LPBF Process
2.2. Design of Experiments
2.2.1. Up-Facing Parameters Optimization
2.2.2. Contour Parameter Optimization
2.3. Surface Quality Characterization
3. Results and Discussion
3.1. Optimization of Up-Facing Skin Parameter
3.2. Contour Parameter Optimization
4. Conclusions
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Factors | Levels | ||||
---|---|---|---|---|---|
(Up-facing) laser power (W) | 40 | 60 | 80 | 100 | 120 |
(Up-facing) scanning speed (mm/s) | 400 | 600 | 800 | 1000 | 1200 |
(Up-facing) hatch distance (mm) | 0.05 | 0.06 | 0.07 | 0.08 | 0.09 |
(Up-facing) beam offset (mm) | 0.04 | 0.06 | 0.08 | 0.1 | 0.12 |
Independent Factors | Coded levels | ||||||
---|---|---|---|---|---|---|---|
Factor A coded | −1 | −0.5 | 0 | 0.5 | 1 | - | - |
Factor B coded | −0.866 | −0.577 | −0.289 | 0 | 0.289 | 0.577 | 0.866 |
Factor C coded | −0.817 | −0.613 | −0.204 | 0 | 0.204 | 0.613 | 0.817 |
Factor D coded | −0.791 | 0 | 0.791 | - | - | - | - |
Factors Contour | Levels | ||||
---|---|---|---|---|---|
(Contour) laser power (W) | 100 | 120 | 140 | 160 | 180 |
(Contour) scanning speed (mm/s) | 1000 | 1300 | 1600 | 1900 | 2200 |
(Contour) beam offset (mm) | 0.07 | 0.08 | 0.09 | 0.1 | 0.11 |
Run | Factors: Up-Facing Skin Parameters | Results | |||
---|---|---|---|---|---|
Power (W) | Scanning Speed (mm/s) | Hatch Distance (mm) | Beam Offset (mm) | Surface Roughness (Ra, μm) | |
1 | 40 | 400 | 0.05 | 0.04 | 13.25 |
2 | 40 | 600 | 0.06 | 0.06 | 13.60 |
3 | 40 | 800 | 0.07 | 0.08 | 14.73 |
4 | 40 | 1000 | 0.08 | 0.10 | 13.86 |
5 | 40 | 1200 | 0.09 | 0.12 | 15.34 |
6 | 60 | 400 | 0.06 | 0.08 | 13.82 |
7 | 60 | 600 | 0.07 | 0.10 | 14.26 |
8 | 60 | 800 | 0.08 | 0.12 | 16.26 |
9 | 60 | 1000 | 0.09 | 0.04 | 15.71 |
10 | 60 | 1200 | 0.05 | 0.06 | 16.57 |
11 | 80 | 400 | 0.07 | 0.12 | 13.86 |
12 | 80 | 600 | 0.08 | 0.04 | 15.92 |
13 | 80 | 800 | 0.09 | 0.06 | 15.69 |
14 | 80 | 1000 | 0.05 | 0.08 | 14.16 |
15 | 80 | 1200 | 0.06 | 0.10 | 15.63 |
16 | 100 | 400 | 0.08 | 0.06 | 11.75 |
17 | 100 | 600 | 0.09 | 0.08 | 12.65 |
18 | 100 | 800 | 0.05 | 0.10 | 11.42 |
19 | 100 | 1000 | 0.06 | 0.12 | 13.80 |
20 | 100 | 1200 | 0.07 | 0.04 | 15.65 |
21 | 120 | 400 | 0.09 | 0.10 | 12.51 |
22 | 120 | 600 | 0.05 | 0.12 | 14.45 |
23 | 120 | 800 | 0.06 | 0.04 | 14.14 |
24 | 120 | 1000 | 0.07 | 0.06 | 11.82 |
25 | 120 | 1200 | 0.08 | 0.08 | 14.49 |
K | Factor: Up-Facing Skin Parameters | |||
---|---|---|---|---|
Power (W) | Scanning Speed (mm/s) | Hatch Distance (mm) | Beam Offset (mm) | |
k1 | 14.15 | 13.04 | 13.97 | 14.93 |
k2 | 15.33 | 14.52 | 14.55 | 14.23 |
k3 | 15.05 | 14.22 | 13.84 | 13.74 |
k4 | 13.05 | 13.87 | 14.46 | 13.53 |
k5 | 13.48 | 15.41 | 14.26 | 14.62 |
R = max(ki) − min(ki) | 2.27 | 2.38 | 0.71 | 1.40 |
Order of factors | 2 | 1 | 4 | 3 |
Run | Coded Levels | Uncoded Level: Up-Facing Parameters | Results | ||||||
---|---|---|---|---|---|---|---|---|---|
A | B | C | D | Hatch Distance (mm) | Laser Power (W) | Scanning Speed (mm/s) | Beam Offset (mm) | Surface Roughness (Ra, μm) | |
1 | 0 | 0 | 0 | 0 | 0.07 | 150 | 700 | 0.08 | 9.41 |
2 | 1 | 0 | 0 | 0 | 0.09 | 150 | 700 | 0.08 | 9.09 |
3 | 0.5 | 0.866 | 0 | 0 | 0.08 | 193 | 700 | 0.08 | 6.92 |
4 | 0.5 | 0.289 | 0.817 | 0 | 0.08 | 164 | 945 | 0.08 | 9.33 |
5 | 0.5 | 0.289 | 0.204 | 0.791 | 0.08 | 164 | 761 | 0.11 | 9.51 |
6 | −1 | 0 | 0 | 0 | 0.05 | 150 | 700 | 0.08 | 10.85 |
7 | −0.5 | −0.866 | 0 | 0 | 0.06 | 107 | 700 | 0.08 | 12.70 |
8 | −0.5 | −0.289 | −0.817 | 0 | 0.06 | 136 | 455 | 0.08 | 10.48 |
9 | −0.5 | −0.289 | −0.204 | −0.791 | 0.06 | 136 | 639 | 0.05 | 11.28 |
10 | 0.5 | −0.866 | 0 | 0 | 0.08 | 107 | 700 | 0.08 | 12.69 |
11 | 0.5 | −0.289 | −0.817 | 0 | 0.08 | 136 | 455 | 0.08 | 11.02 |
12 | 0.5 | −0.289 | −0.204 | −0.791 | 0.08 | 136 | 639 | 0.05 | 12.28 |
13 | −0.5 | 0.866 | 0 | 0 | 0.06 | 193 | 700 | 0.08 | 7.84 |
14 | 0 | 0.577 | −0.817 | 0 | 0.07 | 179 | 455 | 0.08 | 9.15 |
15 | 0 | 0.577 | −0.204 | −0.791 | 0.07 | 179 | 639 | 0.05 | 9.46 |
16 | −0.5 | 0.289 | 0.817 | 0 | 0.06 | 164 | 945 | 0.08 | 10.02 |
17 | 0 | −0.577 | 0.817 | 0 | 0.07 | 121 | 945 | 0.08 | 12.03 |
18 | 0 | 0 | 0.613 | −0.791 | 0.07 | 150 | 884 | 0.05 | 11.13 |
19 | −0.5 | 0.289 | 0.204 | 0.791 | 0.06 | 164 | 761 | 0.11 | 10.13 |
20 | 0 | −0.577 | 0.204 | 0.791 | 0.07 | 121 | 761 | 0.11 | 12.78 |
21 | 0 | 0 | −0.613 | 0.791 | 0.07 | 150 | 516 | 0.11 | 10.46 |
22 | 0 | 0 | 0 | 0 | 0.07 | 150 | 700 | 0.08 | 10.71 |
23 | 0 | 0 | 0 | 0 | 0.07 | 150 | 700 | 0.08 | 10.31 |
24 | 0 | 0 | 0 | 0 | 0.07 | 150 | 700 | 0.08 | 10.17 |
25 | 0 | 0 | 0 | 0 | 0.07 | 150 | 700 | 0.08 | 10.75 |
Headings | Factors: Contour Parameters | Results | ||
---|---|---|---|---|
Power (W) | Scanning Speed (mm/s) | Beam Offset (mm) | Surface Roughness (Ra, μm) | |
1 | 100 | 1000 | 0.07 | 5.49 |
2 | 100 | 1300 | 0.08 | 5.82 |
3 | 100 | 1600 | 0.09 | 8.18 |
4 | 100 | 1900 | 0.1 | 12.20 |
5 | 100 | 2200 | 0.11 | 16.77 |
6 | 120 | 1000 | 0.08 | 6.22 |
7 | 120 | 1300 | 0.09 | 6.48 |
8 | 120 | 1600 | 0.1 | 7.10 |
9 | 120 | 1900 | 0.11 | 17.52 |
10 | 120 | 2200 | 0.07 | 14.55 |
11 | 140 | 1000 | 0.09 | 7.51 |
12 | 140 | 1300 | 0.1 | 7.92 |
13 | 140 | 1600 | 0.11 | 9.80 |
14 | 140 | 1900 | 0.07 | 11.26 |
15 | 140 | 2200 | 0.08 | 12.98 |
16 | 160 | 1000 | 0.1 | 6.91 |
17 | 160 | 1300 | 0.11 | 9.03 |
18 | 160 | 1600 | 0.07 | 9.25 |
19 | 160 | 1900 | 0.08 | 10.43 |
20 | 160 | 2200 | 0.09 | 12.92 |
21 | 180 | 1000 | 0.11 | 7.53 |
22 | 180 | 1300 | 0.07 | 9.47 |
23 | 180 | 1600 | 0.08 | 9.91 |
24 | 180 | 1900 | 0.09 | 10.53 |
25 | 180 | 2200 | 0.1 | 11.78 |
Source | A | B | C | AB | AC | BC | A2 | B2 | C2 |
---|---|---|---|---|---|---|---|---|---|
p-value | 0.453 | 0.000 | 0.462 | 0.005 | 0.008 | / | 0.818 | 0.000 | 0.015 |
Source | Degrees of Freedom | Sum of Squares | Mean Square | F Value | p Value | Heading |
---|---|---|---|---|---|---|
Model | 7 | 188.65 | 26.95 | 72.61 | 0.000 | Significant |
A-Laser power | 1 | 0.233 | 0.233 | 0.63 | 0.440 | |
B-Scanning speed | 1 | 107.32 | 107.32 | 289.12 | 0.000 | |
C-Beam offset | 1 | 0.223 | 0.223 | 0.60 | 0.449 | |
B2 | 1 | 9.488 | 9.488 | 25.56 | 0.000 | |
C2 | 1 | 2.933 | 2.933 | 7.90 | 0.012 | |
AB | 1 | 4.092 | 4.092 | 11.02 | 0.004 | |
AC | 1 | 3.542 | 3.542 | 9.54 | 0.007 | |
Error | 17 | 6.310 | 0.371 | |||
Total | 24 | 194.96 |
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Gao, C.; Tang, H.; Zhang, S.; Ma, Z.; Bi, Y.; Rao, J.-H. Process Optimization for Up-Facing Surface Finish of AlSi10Mg Alloy Produced by Laser Powder Bed Fusion. Metals 2022, 12, 2053. https://doi.org/10.3390/met12122053
Gao C, Tang H, Zhang S, Ma Z, Bi Y, Rao J-H. Process Optimization for Up-Facing Surface Finish of AlSi10Mg Alloy Produced by Laser Powder Bed Fusion. Metals. 2022; 12(12):2053. https://doi.org/10.3390/met12122053
Chicago/Turabian StyleGao, Chaofeng, Huaping Tang, Shiheng Zhang, Zhibo Ma, Yunjie Bi, and Jeremy-Heng Rao. 2022. "Process Optimization for Up-Facing Surface Finish of AlSi10Mg Alloy Produced by Laser Powder Bed Fusion" Metals 12, no. 12: 2053. https://doi.org/10.3390/met12122053