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

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

Research output: Chapter in Book/Report/Conference proceedingConference contribution

1 Citation (Scopus)


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.
Original languageEnglish
Title of host publication5th CIRP CSI 2020
Publication statusPublished - 2020


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


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