Effect of laser power on formability, microstructure and mechanical properties of selective laser melted Mg-Al-Zn alloy

Purpose This paper aims to study the effect of laser energy on the formability, microstructure and mechanical properties of AZ61D alloy to assist systematic study of laser additive manufacturing of magnesium alloys. Design/methodology/approach In this study, porous magnesium alloy samples were prepared by using different laser parameters. The changes of the formability and microstructure were observed by SEM, and the mechanical properties were tested. The above results were analyzed to obtain optimized laser parameters. Findings When the laser power is between 85 and 95 W (pulse width 3.0 ms, frequency 40 Hz), the surface morphology of the selective laser-melted (SLMed) porous samples are smooth and even. At 80 W, SLMed porous samples have a maximum relative density of 99.2 per cent. Because of the "solute capture" effect and the evaporization of magnesium, the fraction of ss-Mg17Al12 increases from 42.1 to 52.1 per cent when power rises from 80 to 105 W. The ultimate compressive strength of SLMed porous magnesium alloys is strengthened with the increase of laser power. Originality/value The effect of laser parameters on microstructure and mechanical properties of porous magnesium alloys prepared by SLM has not been reported.