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<p>In this paper, we present the results of single-track experiments conducted for different fractions of standard AlSi10Mg powder, which were sieved to achieve varying mean size of the particles. Significant differences in the melting behaviour of these fractions were observed at relatively low input energy levels during laser powder bed fusion (LPBF). Namely, a remarkable particle size effect is observed in the position of lack of fusion boundary on the process map of laser power and velocity. We established that this boundary corresponds to an approximately constant linear energy density at low levels of Peclet number (Pe &lt; 2), while the constant enthalpy density defines it at higher levels (Pe &gt; 2). Specifically, for mean particle sizes ranging from 28 to 64 <InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(\upmu \)</EquationSource> <EquationSource Format="MATHML"><math> <mi mathvariant="normal">μ</mi> </math></EquationSource> </InlineEquation>m, the required linear energy density for stable track formation ranges from 50 to 167 J/m and the nominal enthalpy density ranges from 4.4 to 15 J/mm<InlineEquation ID="IEq2"> <EquationSource Format="TEX">\(^3\)</EquationSource> <EquationSource Format="MATHML"><math> <mmultiscripts> <mrow /> <mrow /> <mn>3</mn> </mmultiscripts> </math></EquationSource> </InlineEquation>. Based on the scaling law analysis and numerical simulations, we show that the observed phenomena should be attributed to the change in absorptivity of the powder layer, which depends on particle size and packing density. The presented results can be useful for the adjustment of LPBF process parameters and powder particle size selection for AlSi10Mg alloy as well as for other highly reflective materials.</p>

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On the influence of powder particle size on single-track formation in laser powder bed fusion of AlSi10Mg alloy

  • 期刊论文

  • 发表日期：

    2026年7月30日

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  • Y. Solyaev,
  • V. Dobryanskiy,
  • Nguyen Long,
  • Stanislav Chernyshikhin

摘要

In this paper, we present the results of single-track experiments conducted for different fractions of standard AlSi10Mg powder, which were sieved to achieve varying mean size of the particles. Significant differences in the melting behaviour of these fractions were observed at relatively low input energy levels during laser powder bed fusion (LPBF). Namely, a remarkable particle size effect is observed in the position of lack of fusion boundary on the process map of laser power and velocity. We established that this boundary corresponds to an approximately constant linear energy density at low levels of Peclet number (Pe < 2), while the constant enthalpy density defines it at higher levels (Pe > 2). Specifically, for mean particle sizes ranging from 28 to 64 \(\upmu \) μ m, the required linear energy density for stable track formation ranges from 50 to 167 J/m and the nominal enthalpy density ranges from 4.4 to 15 J/mm \(^3\) 3 . Based on the scaling law analysis and numerical simulations, we show that the observed phenomena should be attributed to the change in absorptivity of the powder layer, which depends on particle size and packing density. The presented results can be useful for the adjustment of LPBF process parameters and powder particle size selection for AlSi10Mg alloy as well as for other highly reflective materials.