Charpy impact testing of direct metal laser sintering of AlSi10Mg alloy: Process Parameters and microstructural investigation
Abstract This study investigates the effect of manufacturing parameters on the impact behavior of Charpy test specimens produced from AlSi10Mg alloy using laser powder bed fusion (LPBF) process. For this purpose, specimens were produced using two layer thicknesses (30 µm and 60 µm), two infill patterns (grid and rectilinear), and three scanning angles (0°, 45°, and 90°). The effects of these parameters on impact toughness were experimentally evaluated. V-notched Charpy impact tests were performed, and the absorbed fracture energy (J) and fracture angle (°) were determined. Fracture surfaces were further examined with scanning electron microscopy (SEM) to evaluate pore morphology, dimple formation, and fusion quality. The results show that absorbed fracture energy decreases as the scan angle increases. Ductile fracture was predominantly observed at 0°, while brittle fracture behavior became dominant at 45° and 90°. Increasing layer thickness reduced interlayer bonding quality, leading to lack-of-fusion defects. Accordingly, the 30 µm specimens generally exhibited a denser microstructure and higher absorbed energy (~9 J). The grid (G) infill pattern provided more stable energy absorption compared to the rectilinear (R) pattern. SEM observations clearly demonstrated the effect of processing parameters. In particular, the 30 µm specimens with rectilinear infill, exhibited homogeneous melt pools and distinct dimple formation, indicating ductile fracture. In contrast, the 60 µm specimens showed larger pores, interlayer fusion defects, and directional tearing characteristics. At a scan angle of 90°, fracture surfaces exhibited a more multidirectional character, while at 0° crack propagation was predominantly uniaxial. The highest impact toughness was obtained for the 30-G-0 condition (~9 J), and the lowest for the 30-R-90 condition (~5 J). The findings indicate that LPBF processing parameters have a decisive effect on the impact strength and fracture morphology of AlSi10Mg alloy. These results provide insight into parameter optimization and a better understanding of microstructure mechanical property relationships in components manufactured with LPBF.
Read more