Effect of the hatch spacing in laser powder bed fusion on the AlSi7Mg aluminum alloy cutting forces and surface finish after turning

Applying additive manufacturing (AM) technologies in fabricating aluminum alloy automotive components can significantly enhance vehicle light-weighting through optimized design. By varying the AM process parameters, the resultant microstructure can be substantially altered, even post-heat treatment. Given that machining operations remain essential in many applications, understanding the impact of the AM parameters on the machining performances is vital. This paper explores how hatch spacing in laser powder bed fusion (LPBF) process affects the machinability of the AlSi7Mg aluminum alloy, in terms of cutting forces and machined surface roughness, providing a correlation with the microstructure induced by both the AM and heat treatment steps. In particular, the research reveals that the larger the hatch spacing the smoother the machined surface, underlining the critical role of this LPBF parameter in determining the final surface quality.