Journal of Powder Materials (한국분말재료학회지)

The Korean Powder Metallurgy & Materials Institute (한국분말재료학회 (*구 분말야금학회))
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A Parametric Study on the L-PBF Process of an AlSi10Mg Alloy for High-Speed Productivity of Automotive Prototype Parts

  • Yeonha Chang (Lightweight Materials Research Team, Hyundai Motor Group) ;
  • Hyomoon Joo (Lightweight Materials Research Team, Hyundai Motor Group) ;
  • Wanghyun Yong (Lightweight Materials Research Team, Hyundai Motor Group) ;
  • Yeongcheol Jo (Lightweight Materials Research Team, Hyundai Motor Group) ;
  • Seongjin Kim (Lightweight Materials Research Team, Hyundai Motor Group) ;
  • Hanjae Kim (Lightweight Materials Research Team, Hyundai Motor Group) ;
  • Yeon Woo Kim (Department for 3D Printing Materials, Korea Institute of Materials Science (KIMS)) ;
  • Kyung Tae Kim (Department for 3D Printing Materials, Korea Institute of Materials Science (KIMS)) ;
  • Jeong Min Park (Department for 3D Printing Materials, Korea Institute of Materials Science (KIMS))
  • Received : 2024.10.15
  • Accepted : 2024.10.21
  • Published : 2024.10.28
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Abstract

The AlSi10Mg alloy has garnered significant attention for its application in laser powder bed fusion (L-PBF), due to its lightweight properties and good printability using L-PBF. However, the low production speed of the L-PBF process is the main bottleneck in the industrial commercialization of L-PBF AlSi10Mg alloy parts. Furthermore, while L-PBF AlSi10Mg alloy exhibits excellent mechanical properties, the properties are often over-specified compared to the target properties of parts traditionally fabricated by casting. To accelerate production speed in L-PBF, this study investigated the effects of process parameters on the build rate and mechanical properties of the AlSi10Mg alloy. Guidelines are proposed for high-speed additive manufacturing of the AlSi10Mg alloy for use in automotive parts. The results show a significant increase in the build rate, exceeding the conventional build rate by a factor of 3.6 times or more, while the L-PBF AlSi10Mg alloy met the specifications for automotive prototype parts. This strategy can be expected to offer significant cost advantages while maintaining acceptable mechanical properties of topology-optimized parts used in the automobile industry.

Keywords

Acknowledgement

This work was supported by the Hyundai Motor Group.

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