Development of a novel laser polishing strategy for additively manufactured AlSi10Mg alloy parts

Mason, Benjamin ORCID: https://orcid.org/0000-0002-2136-3252, Ryan, Michael ORCID: https://orcid.org/0000-0002-8104-0121, Setchi, Rossitza ORCID: https://orcid.org/0000-0002-7207-6544, Kundu, Abhishek ORCID: https://orcid.org/0000-0002-8714-4087, Nishio Ayre, Wayne ORCID: https://orcid.org/0000-0003-2405-1876 and Bhaduri, Debajyoti ORCID: https://orcid.org/0000-0002-8270-388X 2022. Development of a novel laser polishing strategy for additively manufactured AlSi10Mg alloy parts. Presented at: 9th International Conference on Sustainable Design and Manufacturing - SDM 2022, Split, Croatia, 16-17 September 2022.

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Abstract

Post-processing of additively manufactured (AM) aluminium alloy parts via laser polishing (LP) is particularly challenging due to the materials’ high thermal conductivity, diffusivity, and reflectivity. Here, a novel multi-step laser polishing strategy, by combining laser ablation and smoothing steps, is developed that effectively reduces the surface roughness of AM AlSi10Mg parts. The min-imum average roughness (Sa) and 10-point height (S10z) are achieved as 1.81 μm and 23.7 μm, representing maximum reductions of 94.1% and 89.8%, respectively, from the as-built AM surfaces (initial Sa 8 – 28 μm). A strong rela-tionship has been observed between the initial surface roughness and the achiev-able roughness reduction. Regarding the other surface integrity factors, sub-sur-face microhardness (between 10-40 μm) after LP increases up to 182 HV0.01, compared to the bulk hardness (105 HV0.01) measured ~60 μm below the surface. Clear evidence of material’s flow within the surface asperities during the LP steps is observed from the cross-sectional microstructures. Further study will involve in-depth analysis of materials’ compositions within the LP-processed layers.

Item Type:	Conference or Workshop Item (Paper)
Status:	Unpublished
Schools:	Dentistry Engineering
Date of First Compliant Deposit:	5 August 2022
Date of Acceptance:	2022
Last Modified:	23 Jan 2025 18:34
URI:	https://orca.cardiff.ac.uk/id/eprint/151735

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