Multi-objective Optimization in Selective Laser Melting of AlSi10Mg Alloy Based on Response Surface Methodology

In this study, a method combining full-factorial experiment and response surface methodology was developed to simultaneously optimize the density and tensile strength of SLMed-AlSi10Mg alloy for the first time, taking into account the economic benefits. Meanwhile, the effects of laser power, scanning speed and their interaction on the relative density (ρ) and tensile strength (R_m) were systematically studied. The results show that ρ is not always positively correlated with R_m. Laser power and scanning speed have a strong interaction on ρ and R_m, especially for R_m. The mathematical models of ρ and R_m constructed have high adaptability, reliability and fitting accuracy. The predicted optimal process parameters are laser power of 340 W and scanning speed of 1870 mm/s, and the corresponding experimental values of ρ and R_m are 99.34% and 328.31 MPa, respectively. Our work provides theoretical guidance and technical support for printing AlSi10Mg alloy with high quality.