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<p>During the selective laser melting (SLM) process, the material undergoes rapid thermal cycles, resulting in significant residual stresses. Suitable process parameters are the key method to decrease these residual stresses. A thermo-mechanical model of AlSi10Mg alloy is established to investigate the effects of layer thickness, interlayer pause time, and laser spacing on residual stress during the SLM process. Studies have shown that components with thicker layers reduce temperature gradients, mitigating thermal stress accumulation. Longer interlayer pauses decrease cooling rates, enhancing heat diffusion and lowering residual stress. Laser spacing influences the heat-affected zone (HAZ); appropriate spacing ensures uniform HAZ distribution, reducing stress concentrations. Response surface analysis revealed that the interlayer pause time exhibited the least influence on residual stress, while the combined effect between layer thickness and interlayer pause time on the residual stress distribution is significant. The combination of parameters to minimize residual stress was predicted using the multi-objective approach as follows: a layer thickness of 0.05&#xa0;mm, an interlayer pause time of 0.001&#xa0;s, and a laser spacing of 0.137&#xa0;mm. The application of optimized process parameters resulted in a reduction in residual stress from 63.9 to 54.6&#xa0;MPa, corresponding to a 14.5% decrease in stress magnitude.</p>

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Effect of Process Parameter on Residual Stress of AlSi10Mg Alloy during Selective Laser Melting

  • 期刊论文

  • 发表日期：

    2025年10月9日

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  • Hongyu Yu,
  • Miao Liu,
  • Yue Sun,
  • Meng Chen,
  • Zheng Liu,
  • Zhongqiu Liu

摘要

During the selective laser melting (SLM) process, the material undergoes rapid thermal cycles, resulting in significant residual stresses. Suitable process parameters are the key method to decrease these residual stresses. A thermo-mechanical model of AlSi10Mg alloy is established to investigate the effects of layer thickness, interlayer pause time, and laser spacing on residual stress during the SLM process. Studies have shown that components with thicker layers reduce temperature gradients, mitigating thermal stress accumulation. Longer interlayer pauses decrease cooling rates, enhancing heat diffusion and lowering residual stress. Laser spacing influences the heat-affected zone (HAZ); appropriate spacing ensures uniform HAZ distribution, reducing stress concentrations. Response surface analysis revealed that the interlayer pause time exhibited the least influence on residual stress, while the combined effect between layer thickness and interlayer pause time on the residual stress distribution is significant. The combination of parameters to minimize residual stress was predicted using the multi-objective approach as follows: a layer thickness of 0.05 mm, an interlayer pause time of 0.001 s, and a laser spacing of 0.137 mm. The application of optimized process parameters resulted in a reduction in residual stress from 63.9 to 54.6 MPa, corresponding to a 14.5% decrease in stress magnitude.