Study on the Morphology and Microstructure Evolution of the Molten Pool in Selective Laser Melting Forming Process of Aluminum Alloy Powder with a Large Layer Thickness of 80 μm
GONG Haijun1,*, WANG Ling1, KANG Hongye2, ZUO Qianlong2, AN Zhiguo1, GAO Zhengyuan1
1 School of Mechatronics and Vehicle Engineering, Chongqing Jiaotong University, Chongqing 400074, China 2 Chongqing Adrayn Technology Co., Ltd., Chongqing 401329, China
Abstract: In order to improve the powder layer thickness and quality stability of the existing aluminum alloy selective laser melting (SLM) forming process, and to reveal the morphology and microstructure evolution of the SLM forming melt pool for thick aluminum alloys, single-layer and multi-layer SLM forming experiments with a layer thickness of 80 μm were conducted on AlSi10Mg alloy. The single channel experiments show that excessive or insufficient energy input can easily cause distortion and spheroidization defects in a single melt. A line energy input of 475.0 J/m and a small wetting angle can make the melt pool easier to spread. When the width-to-depth ratio of the melt pool was greater than 1, an ideal straight single melt pool can be obtained; the fluctuation degree of the solidification trajectory of the multi-melt pool is closely related to the laser power. The overlap rate decreases with the increase of scanning spacing, and the surface of the melt pool becomes more spheroidized and grooved. However, the higher the overlap rate, the lower the density. The optimal density can be obtained when the overlap rate is 57.1%. The microstructure analysis of multi-layer samples shows that the metallurgical bonding ability was improved after overlapping between single-layer and multi-layer, multi-layer and multi-layer remelting, and thermal influence. The microstructure presents a honeycomb structure, similar to the microstructure with small layer thickness and similar mechanical properties. Its density can reach 99.24%, and the forming efficiency can reach 31.7 cm3/h. This work successfully applied the thick layer forming process to SLM forming of a certain water pump impeller component, providing a theoretical reference for obtaining high-strength, dense, and high-performance aluminum alloy parts.
龚海军, 王玲, 亢红叶, 左乾隆, 安治国, 高正源. 铝合金粉末80 μm大层厚SLM成型熔池形貌与组织演变[J]. 材料导报, 2025, 39(16): 24080006-7.
GONG Haijun, WANG Ling, KANG Hongye, ZUO Qianlong, AN Zhiguo, GAO Zhengyuan. Study on the Morphology and Microstructure Evolution of the Molten Pool in Selective Laser Melting Forming Process of Aluminum Alloy Powder with a Large Layer Thickness of 80 μm. Materials Reports, 2025, 39(16): 24080006-7.
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2025, Vol. 39 
