A state-of-the-art direct metal laser sintering of Ti6Al4V and AlSi10Mg alloys: Surface roughness, tensile strength, fatigue strength and microstructure

• Published in: Optics and laser technology 2021-11, Vol.143, p.107366, Article 107366
• Main Authors: Ishfaq, Kashif, Abdullah, Mirza, Mahmood, Muhammad Arif
• Format: Article
• Language: English
• Subjects: 3D printing; Alloy powders; Aluminum alloy; Aluminum base alloys; Corrosion resistance; Direct metal sintering process; Fatigue strength; Flux density; Heat treating; Laser beams; Laser sintering; Micro-structure; Microhardness; Microstructure; Post-processing; Process parameters; Rapid prototyping; Sintering (powder metallurgy); Surface roughness; Surface treatment; Tensile strength; Three dimensional printing; Titanium alloy; Titanium base alloys; Weight reduction
• ISSN: 0030-3992; 1879-2545
• DOI: 10.1016/j.optlastec.2021.107366

•This review focuses on the direct metal laser sintering of Ti6Al4V and AlSi10Mg alloys.•Influence of primary parameters on the microstructure of the printed parts are discussed.•Effect of microstructure on hardness, fatigue behavior and stress–strain curve are compiled.•A brief comparison is made for previous studies in case of Ti6Al4V and AlSi10Mg alloys.•Besides, future outlook is presented in the field of direct metal laser sintering. Direct metal laser sintering (DMLS), a 3D printing technique, can produce high strength and good corrosion resistance parts. DMLS utilizes the powder particles partially melted by the laser beam. In DLMS, titanium (Ti6Al4V) and aluminum (AlSi10Mg) alloys have shown their potential in biomedical and automotive fields. This review focuses on the DMLS of Ti6Al4V and AlSi10Mg alloy powder particles. The effects of laser energy density, scanning speed, and various other parameters on the micro-hardness, fatigue strength, and microstructure of the manufactured part are presented. The review concluded that the operating process parameters and post-processing, including heat and surface treatments, performed on the printed part greatly influence the microstructure, hardness, and fatigue strength. Such processes increase hardness and fatigue strength. The pores and voids and satellite objects become the reason for the failure of parts.