Comparison of AlSi10Mg and Al 6061 Processed through DMLS

Abstract

Direct Metal Laser Sintering (DMLS) processing of aluminum alloys has been primarily limited to a casting grade of aluminum, AlSi10Mg. The reasons for the choice of AlSi10Mg by machine manufacturers are presently unknown; however, it is suspected that the reduced coefficient of thermal expansion (CTE) due to the presence of Silicon may enhance DMLS processability. Aluminum 6061 (Al 6061) is a commonly used alloy across a wide range of industries and applications, and Harvest has observed a high interest in DMLS-manufactured Al 6061 products. However, the higher CTE value potentially presents greater challenges in controlling the shrinkage-induced warp common during DMLS. The work presented in this paper was performed in an effort to understand differences in manufacturability as well as mechanical properties of DMLS-processed AlSi10Mg and Al 6061.