On the surface integrity of additive manufactured and post-processed AlSi10Mg parts

Debajyoti Bhaduri*, Pavel Penchev, Stefan Dimov, Khamis Essa, Luke N. Carter, Catalin I. Pruncu, Jun Jiang, Daniele Pullini

*Corresponding author for this work

Research output: Contribution to journalConference articlepeer-review

8 Citations (Scopus)
1 Downloads (Pure)


The research centres on the evaluation of surface integrity of AlSi10Mg parts produced via laser-based powder bed fusion (LPBF) process, followed by vibratory surface finishing. The alloy is chosen for its applications in lightweight components used in electronic packaging, automotive and aerospace sectors. Initial experiments involve optimisation of key LPBF process parameters by analysing the surface roughness and density data of the built parts. A Taguchi L18 orthogonal array is used for the optmisation trials with variations in the laser power (P), beam scanning speed (v), hatch spacing (H) and island size (I). Latter experimental phase deals with microhardness and microstructure assessment of heat treated LPBF specimens that are produced using the optimised LPBF parameters, i.e. P: 250 W, v: 1500 mm/s, H: 75 μm and I: 2 mm. Microhardnesses of the annealed samples reduce by ~12% with respect to the as-built parts and the values remain almost unchanged from the annealed state following solution treatment and ageing. The fish-scale like melt-pools observed on the unheat treated samples begin to fade off in the annealed specimens and completely disappear after solution treatment and ageing, with silicon particles dispersed all over the aluminium matrix. The final experimental phase involves vibratory surface finishing of the as-built LPBF parts using a vibrating ceramic media mixed with different acid and amine based liquid compounds for 1-6 hours, followed by vibrating in a maize based media for another 1-6 hours. The process aids in reducing the parts' roughness, Sa by ~35-70%, however the effect is more prominent when using the ceramic media.

Original languageEnglish
Pages (from-to)339-344
Number of pages6
JournalProcedia CIRP
Publication statusPublished - 31 May 2020
Event5th CIRP Conference on Surface Integrity, CSI 2020 -
Duration: 1 Jun 20205 Jun 2020

Bibliographical note

Publisher Copyright:
© 2020 The Author(s).


  • aluminium
  • Laser-based powder bed fusion
  • surface integrity

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Industrial and Manufacturing Engineering


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