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Description
Selective Laser Melting (SLM), a laser powder bed fusion process, enables fabrication of complex AlSi10Mg components with high dimensional accuracy. However, achieving near-fully dense parts remains challenging because porosity is strongly influenced by the interaction of processing parameters. While previous studies have extensively investigated effects of laser power and scanning speed, the influence of laser spot diameter on porosity has received less attention. Moreover, most numerical studies focus on melt pool characteristics without quantitatively assessing porosity tendency. This study proposes a Numerical Porosity Index (NPI) derived from predicted melt pool volume using a three-dimensional transient thermal finite element model developed in ANSYS. A combined Design of Experiments (DOE), Finite Element Method (FEM), and Response Surface Methodology (RSM) framework investigated the effects of laser power, scanning speed, and laser spot diameter on porosity tendency and identified the optimal processing window. Results showed that all three parameters significantly affected the NPI, with laser spot diameter strongly influencing melt pool stability. Optimization identified an optimum processing window of 154–164 W, 804–866 mm/s, and a 0.08 mm laser spot diameter, corresponding to minimum porosity tendency. Numerical predictions agreed well with experimental microstructural characterization and melt pool dimensions, demonstrating the effectiveness of the proposed framework.
| Topic Area | Design Optimization, Additive Manufacturing Technologies & Applications |
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