1 School of Materials Science and Engineering, University of Shanghai for Science and Technology, Shanghai 200093, China; 2 Shanghai Aircraft Design and Research Institute, Shanghai 201210, China; 3 Monash Centre for Additive Manufacturing, Monash University, Clayton 3800, Australia
Abstract: As an additive manufacturing technology, selective laser melting (SLM) is capable of forming complex structures with high forming precision and is suitable for rapid prototyping of complex?structure components made of aluminum alloys. Due to their high specific strength and excellent mechanical properties, aluminum alloys are widely used in aerospace, automobile, and other industries that require lightweight materials. However, SLM aluminum alloys are prone to cracks, pores, residual stress, anisotropy, and balling. Defects are mainly caused by inappropriate process parameters and can restrict the use of SLM aluminum alloys. Therefore, insights into the formation mechanism of these defects can help control and mitigate their effects.
In this study, the common Al?Si cast aluminum alloy was used to review the current state of research on the defect formation mechanism of SLM aluminum alloys. This paper summarizes the effects of different process parameters on the defect formation and examines the relationship between defects and the mechanical properties of aluminum alloys. High porosity can reduce tensile strength and negatively affect the fatigue properties; however, fatigue resistance can be increased via an appropriate post?treatment.
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