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Channels manufactured by laser powder bed fusion have an inherent process-induced dross formation and surface texture that require proper characterization for design and process optimization. This work undertakes surface texture characterization of AlSi10Mg channels of nominal diameter sizes ranging from 1 mm to 9 mm using X-ray computed tomography. Profile parameters, including Pa, Pz, and Pq, were found to be interchangeable for qualitative characterization of surface texture variation. Psk, Pvv, and the fractal dimension could identify the presence of extreme dross and sintered particles on the measured profiles. A method for predicting the equivalent diameter of the unobstructed cross-sectional area (Deq) was presented and its reduction was found to follow a logarithmic trend, as a function of channel length. An empirical model Pa (β, D), as a function of local angular position (β) and channel diameter (D), was demonstrated on a perfect channel geometry, resulting in well-predicted roughness and internal geometry.

Characterization of Geometry and Surface Texture of AlSi10Mg Laser Powder Bed Fusion Channels Using X-ray Computed Tomography