Surface Topographic Features after Milling of Additively Manufactured AlSi10Mg Aluminum Alloy

Abstract

The article presents selected issues related to material quality manufactured by selective laser sintering of AlSi10Mg alloy powder after milling. The workpiece was prepared and machined by down-milling and up-milling with tools made of high-speed steel. Breaches, pores and failure-like cracks on the machined surface were found, which negatively influenced the values of 3D surface roughness parameters. The occurring phenomena were analyzed and proposals for their explanation were made. The results of this research describe the effect of cutting parameters (the feed rate of f = 0.013–0.05 mm/tooth) on the values of parameters describing the surface quality and benchmarks. Topography measurements and 3D surface roughness parameters are presented, as well as the results of microscopic surface analysis. It was found that for aluminum alloy produced by the direct metal laser sintering (DMLS) method, the recommended machining method is down-milling.