Laser Powder-Bed Fusion (LPBF) additive manufacturing (AM) has been used for the production of ferrous alloys, e.g. steel, and stainless steel, as well as non-ferrous alloys, e.g. nickel, titanium, and aluminum. Aluminum AlSi10Mg has been widely used in aluminum AM applications. However; despite its widespread use in the aerospace and defense industry, limited published efforts have provided details about process control and understanding the relationships between key process input variables (KPIVs) and key process output variables (KPOVs). This effort sought to determine the effect of key noise factors and their impact on the process by examining the mechanical properties, dimensional stability, surface finish, porosity, and microstructure as a function of select KPIVs. A Production Readiness Review (PRR) methodology was applied to systematically evaluate the variables that attribute the statistical variance in the processing and post processing of AlSi10Mg. The KPIVs were identified with fishbone analysis to weigh and control noise factors with respect to the key process outputs variable (KPOV’s). Results implied that the post processing of AlSi10Mg, particularly the stress relief parameters, has a statistically significant impact on the KPOVs.
- Identify Key Process Input Variables (KPIVs) that contribute to variability in Laser Powder Bed Fusion Additive Manufacturing.
- Adopt a systematic approach to control variability in laser powder-bed fusion processes using a production readiness review framework.
- Understand the importance of a controlled stress relief following the build process to ensure consistent mechanical properties.