Experimental Study on Circular Overhang Circularity and Surface Quality in AlSi10Mg Manufactured by Laser Powder Bed Fusion

This study investigates the effects of laser power, scan speed, and build height on the circularity and surface quality of AlSi10Mg parts produced through the laser powder bed fusion (LPBF) process. A full factorial experimental design was implemented, and ANOVA was used to analyze the results. The findings reveal that laser power and scan speed significantly influence both circularity and surface roughness, while build height has a minimal effect. Specifically, lower laser power combined with higher scan speed improved circularity, while smoother surface finishes were achieved with higher laser power and higher scan speed. Regression models were developed to predict these outcomes, demonstrating strong explanatory power for circularity and surface roughness. Practical recommendations are provided to optimize LPBF process parameters, such as adjusting laser power and scan speed, and implementing control charts for monitoring circularity during production. Additionally, the study suggests areas for further investigation, including the effect of part positioning relative to argon flow within the build chamber. Overall, these results contribute to a deeper understanding of how key process parameters can be fine-tuned to improve the quality of parts produced by LPBF.