Comprehensive study on statistical methods for optimization of process parameters and material properties of AlSi10Mg in laser powder bed fusion

This study provides a systematic investigation of the effects of process parameters and heat treatments on the material properties of AlSi10Mg, produced by laser powder bed fusion (L-PBF). Using a central composite design (CCD) with 106 test specimens (49 cubes, 57 tensile), the samples were studied for key properties: density (up to 99.96%), hardness (up to 154.6 HV1), surface roughness (as low as 1.9 Ra), tensile strength (up to 487.5 MPa), and elongation at break (up to 16.6%). Statistical analysis (ANOVA) identified laser power and scanning speed as the most influential parameters on these properties. Additionally, heat treatment was shown to reduce hardness and tensile strength but increase elongation at break, demonstrating the ability to modify mechanical properties based on the desired outcome. Process parameter optimization yielded properties comparable to some of the highest reported values for AlSi10Mg in the literature. The study also discusses the transferability and reproducibility of L-PBF results across different machines, highlighting challenges related to machine-to-machine variations, lack of calibration and standardization and parameter consistency. The results demonstrate the potential of L-PBF to produce AlSi10Mg parts with tailored properties for industrial applications.