- Research Article
- 10.2497/jjspm.25-00033
Effect of Layer Thickness on Densification of Aluminum Alloy Powder with Broad Particle Size Distribution by L-PBF Additive Manufacturing
- Apr 15, 2026
- Journal of the Japan Society of Powder and Powder Metallurgy
- Tomofumi Mochizuki + 8 more +8
Additive manufacturing (AM) has become the subject of attention because it can build parts with structures that cannot be achieved by conventional methods. However, one hindrance that has been pointed out to the widespread use of the laser powder bed fusion (L-PBF) method, a type of AM technology, is its high manufacturing costs. An effective method of reducing these costs is reducing manufacturing times and using inexpensive powder. In this research, specimens were built through the L-PBF method by varying the layer thickness using aluminum alloy (AlSi10Mg) broad powder, which included unused coarse powder. Furthermore, we investigated the effects of the particle size distribution of powders and the layer thickness at the time of manufacturing on the relative density of the as-built specimens. As a result, the relative density of the as-built specimen using broad powder was higher than that of a specimen using the existing powder. Although the fabrication conditions of the high-density specimens were limited if the layer was thick, by increasing the layer thickness from 60 µm (conventional value) to 120 µm and adjusting the fabrication conditions, the building speed was increased by 45% while obtaining high-density specimens.
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