Composite powder consolidation using selective laser melting: Input energy/porosity morphology/balling effect relation

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


Colleges, School and Institutes

External organisations

  • American University in Cairo
  • The Advanced Materials Processing Lab. (AMPLAB)


In this study AlSi10 Mg/Al2O3 composite was processed via selective laser melting. The influence of different process parameters namely, laser power, scan speed and hatch spacing was investigated to determine their effect on the physical and mechanical properties of the consolidated powders. Input energy and balling effect, had a major influence on the developed pore morphology. Poor consolidation associated with poor heat diffusion and insufficient melting occurred at the low input energy. Intermediate input energy resulted in the formation of continuous porosity along the building direction separated by consolidated zones of equal width and associated with uniform balling effect. High input energy developed distorted porosity with non-uniform distribution associated with irregular course balling. The formed continuous porosity is attributed to the segregation and migration of alumina particles to the spacing between the deposited successive powder layers followed by their selective melting forming oxide films that acts as a barrier to the complete solidification.


Original languageEnglish
Title of host publicationTMS 2017 146th Annual Meeting
Publication statusPublished - 21 Feb 2017
Event146th Annual Meeting and Exhibition Supplemental, TMS 2017 - San Diego, United States
Duration: 26 Feb 20172 Mar 2017

Publication series

NameMinerals, Metals and Materials Series
VolumePart F6
ISSN (Print)2367-1181
ISSN (Electronic)2367-1696


Conference146th Annual Meeting and Exhibition Supplemental, TMS 2017
CountryUnited States
CitySan Diego


  • AlSi10 Mg/AlO composite, Porosity analysis, Selective laser melting