Evaluation of surface/interface quality, microstructure and mechanical properties of hybrid additive-subtractive aluminium parts

A disadvantage of selective laser melting (SLM) processes for the manufacture of large parts is their slow build time per unit volume. A hybrid route is to generate core simple shapes traditionally, for example by machining, followed by adding final features by SLM. Here the mechanical integrity of such hybrid parts is studied, choosing the building of AlSi10Mg by SLM on a machined AA6082 base, in the shape of a tensile test piece, as a simple example. These materials are chosen for their relevance to lightweight parts. As-built parts fail at the SLM/machined interface but standard heat treatments transfer failures to the machined material. Optimised SLM processing conditions and microstructures of the SLM and interfacial regions are reported.