Investigation of processing windows in additive manufacturing of AlSi10Mg for faster production utilizing data-driven modeling

To reduce production time and decrease production cost, the increase of layer thickness is an adequate option in powder bed fusion. In order to determine the relationships between process parameters in laser powder bed fusion (PBF-LB/M) and final porosity in AlSi10Mg, samples were processed following a space-filling experimental design in the present study. A total of 144 samples were fabricated considering layer thicknesses of 30 µm, 45 µm, 60 µm, and 90 µm. Afterwards, porosity was assessed using image analysis and computed tomography. Different types of defects were found as expected, however, fully dense parts were realized in case of every considered layer thickness. Predictive models were developed using data-driven approaches, eventually enabling multivariate analysis of the correlations and determination of appropriate processing conditions resulting in both low porosity of parts and high build rates.