Powder bed fusion of AlSi10Mg using an electron beam - Processability, microstructure and mechanical properties

Abstract

Powder bed fusion additive manufacturing processes of metals using an electron beam
(PBF-EB/M) and a laser beam (PBF-LB/M) are methods for producing complex near-net-shape
parts layer upon layer, which are standardized in DIN EN ISO/ASTM 52900. Although the
manufacturing processes are extensively used in research and industry, the processing of
aluminum alloys with high specific strength, such as AlSi10Mg, is only applied and scientifically
covered in laser powder bed fusion, but not yet in electron beam powder bed fusion using a spotbased exposure approach. Based on powder feedstock characterization, this study focuses on
the processability, element evaporation, and properties of AlSi10Mg samples processed by
electron beam powder bed fusion. Obtained properties are compared with those reported for
AlSi10Mg processed by PBF-LB/M. Manufactured samples achieve 99.9 % relative density and a
Vickers hardness of up to 52 HV1. Tensile properties show lower tensile strengths of up to
152 MPa but superior elongation at break values of up to 27 % compared to PBF-LB/M.