Abstract

Pore emergence during the laser powder bed fusion (LPBF) technique significantly impairs mechanical characteristics. Therefore, the elimination of pores is a pressing issue to ensure the quality and productivity of manufactured components. The objective of this study is to evaluate how certain parameters, such as laser power, layer thickness, exposure time, hatch distance, and volumetric energy density, affect the microstructure and tensile properties of AlSi10Mg specimens generated by LPBF in both their original state and after undergoing a solution heat treatment. The volumetric energy density (VED) is often used to optimize process parameters in the LPBF approach since it thoroughly evaluates all four main factors. This article specifically examines the impact of VED on the microstructural features and tensile characteristics of printed parts. The high VED of 78.13 J mm−3 decreases the occurrence of porosity and defects, hence enhancing the tensile characteristics of the specimens produced. Regarding specimens that have undergone solution heat treatment, the recommendation is to decrease the laser power to 350 W, which results in a VED of 60.76 J mm−3 and outstanding tensile characteristics. These findings provide fresh perspectives to achieve improved tensile properties of AlSi10Mg parts using LPBF processing settings.