Abstract
In the context of the Design for Additive Manufacturing (DfAM), the elimination and/or reduction of support structures for the parts is a key issue for process optimization in terms of sustainability and surface quality. In this work, the assessment of the surface quality of overhanging thin walls and unsupported holes with different diameters (4, 6, 8 mm) was carried out through confocal microscopy, SEM-EDS analysis and CMM measurements. To this aim, two different types of AlSi10Mg alloy parts were produced with the L-PBF technology, having self-supporting features such as thin walls and holes with different overhang angles. The results showed that (i) unsupported, down-facing surfaces can be printed consecutively without supports up to a 30° overhang angle and with a surface roughness (Sa) ranging from 3 to 40 µm; (ii) unsupported holes can be produced as well, having a mean circularity tolerance ranging from 0.03 to 0.55 mm, regardless of the diameter value; (iii) density and microstructure analysis both revealed that the parts’ integrity was not affected by the design choices.
Subject
General Materials Science,Metals and Alloys
Reference29 articles.
1. Gibson, I., Rosen, D.W., and Stucker, B. Additive Manufacturing Technologies, Springer. [3rd ed.].
2. Laser Powder Bed Fusion for Metal Additive Manufacturing: Perspectives on Recent Developments;Sing;Virtual Phys Prototyp,2020
3. Yadroitsev, I., Yadroitsava, I., Du Plessis, A., and MacDonald, E. (2021). Fundamentals of Powder Bed Fusion of Metals, Elesevier.
4. Defect Characteristics and Analysis of Their Variability in Metal L-PBF Additive Manufacturing;Sanaei;Mater. Des.,2019
5. Gouveia, R.M., Silva, F.J.G., Atzeni, A., Sormaz, D., Alves, J.A., and Pereira, A.B. (2020). Effect of Scan Strategies and Use of Support Structures on Surface Quality and Hardness of L-PBF AlSi10Mg parts. Materials, 13.