Fabrication of Al-11.2Si Components by Direct Laser Metal Deposition for Automotive Applications

Abstract

Recently, Al-Si alloys samples have been manufactured at lab scale using various additive manufacturing processes, but so far there is no literature available to investigate the feasibility of fabricating Al-Si alloy component for automotive component applications using Direct Laser Metal Deposition (LMD) technique. This paper deals with the practical challenges of building single wall and block deposition (cuboid shapes) of eutectic Al-Si alloy using direct laser metal deposition process for developing automotive applications. Two scanning pattern, hatch pattern and single wall pattern were chosen to study the effect of scanning direction on mechanical properties as well as microstructural evolution. Microstructural investigation of single wall and block deposition using optical and scanning electron microscopy revealed a 99.9% dense component with very fine hypoeutectic microstructure. Tensile test sample extracted from block deposition showed an impressive elongation of 9% with an ultimate tensile strength of 225 MPa and tensile test sample of single wall showed an average elongation of 9.4% with an ultimate tensile strength of 225 MPa. This investigation revealed that direct laser metal deposition could successfully print the eutectic Al-Si alloy bracket on shock tower hood without any distortion or bending.