The influence mechanisms of re-fused scanning on the surface roughness, microstructural evolution and mechanical properties of laser powder bed fusion processed AlMgScZr alloy

Laser powder bed fusion (LPBF) stands out as the foremost method for achieving intricate structure with superior design flexibility among additive manufacturing technologies. Within the LPBF process, surface roughness serves as a critical metric governing both fabrication precision and build quality. This study delves into the evolution of the top and side surface roughness as re-fused scanning times increase in LPBF-fabricated AlMgScZr alloy. Concurrently, the investigation evaluates alterations in microstructural characteristics and mechanical properties. Various characterization techniques, including confocal laser scanning microscope, scanning electron microscope, X-ray diffraction, electron backscatter diffraction, as well as tensile and microhardness tests, are employed. The findings concerning the top surface reveal that the initial application of re-fused scanning contributes to enhanced surface roughness. This improvement stems from refined grain structures and induced lattice distortions, facilitated by rapid heat dissipation and thermal recycling within the solidified layer. Consequently, microhardness increases. However, introducing the subsequent re-fused scanning exacerbates surface roughness and instigates Marongoni flow instability, magnesium depletion, and alterations in lattice structures. Moreover, with increasing the re-fused times, there is a noticeable enhancement in preferential crystallite growth orientation along the (200)alpha-Al crystal plane. Regarding the side surface, escalating re-fused times correlate with deteriorating roughness and alterations in molten pool shape and size, attributable to successive energy input. Despite these surface variations, minimal differences are observed in yield strength, tensile strength, and elongation. In essence, this research offers valuable insights into selecting optimal scanning methodologies during the LPBF process, thus guiding improvements in fabrication precision and component quality.