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Definition of the main process parameters, laser power ( P ), scanning speed ( v ), hatching distance ( h d ) and scanning strategy useful for producing dense samples, is fundamental to develop novel alloy compositions for Laser Powder Bed Fusion (LPBF). The present work has two aims: on one side, to verify the processability of a new AlSi10Mg + 4Cu alloy of mixed powders by LBPF; on the other side, on the basis of the experimental analysis, to define a method for processing new alloys. Producing Single Scan Tracks (SSTs), samples with unidirectional scanning strategy and samples with 67° rotated scanning strategy, the proper P - v-h d combinations were identified reaching a final porosity lower than 1.5%. A scenario of hardness and build-up rate vs. energy density is given, to adopt the main process parameters suitable to maximize mechanical properties or productivity. According to the novel method, P - v-h d combinations can be defined through the production and characterization of SSTs and samples with 67° rotated scanning strategy. Through two production steps dense samples can be then obtained, allowing the development of new compositions saving time and reducing costs related to the powder usage.

A time-saving and cost-effective method to process alloys by Laser Powder Bed Fusion