Abstract

AlSi10Mg alloy is recognized for its excellent properties, including low density, superior corrosion resistance, good mechanical strength, high thermal conductivity, and strong compatibility with additive manufacturing (AM). These attributes make it a suitable and versatile material for applications in the automotive and aerospace industries. The optimal combination and influence of process parameters such as laser power, scan speed, hatch spacing, and border laser power significantly affect structural properties, including ultimate tensile strength (UTS), yield strength, scratch resistance, density, ductility, and surface finish. Experiments were conducted to investigate the effects of these parameters on the microstructure and structural properties of the printed samples. The laser power ranged from 250 W to 300 W, scan speed varied from 1800 mm/s to 2200 mm/s, hatch spacing ranged from 60 µm to 100 µm, and border laser power was varied between 325 W and 375 W. In this study, principal component analysis (PCA) was employed to determine the optimal printing process parameters, identify the most influential factors, and evaluate their impact on the quality of fabricated AlSi10Mg components. The microstructure and structural properties of the as-built (untreated) samples were examined. The findings indicate that laser power and scan speed together account for 73.34% of the total variation and play a fundamental role in enhancing product quality. The results also confirm that PCA is an effective tool for optimizing process parameters.

Keywords

AlSi10Mg alloy, Additive manufacturing, Laser process parameters, Principal component analysis (PCA), Microstructure, Mechanical properties.

Cite this article

Gite RE, Wakchaure VD, Nagare PN, Chaudhari SB, Kadhane SB. Effect of SLM process parameters on microstructure and mechanical properties of AlSi10Mg alloy: a PCA approach. International Journal of Advanced Technology and Engineering Exploration. 2026;13(135):160-188. DOI : 10.19101/IJATEE.2025.121220110

References

[1] Wang L, Jiang X, Zhu Y, Zhu X, Sun J, Yan B. An approach to predict the residual stress and distortion during the selective laser melting of AlSi10Mg parts. The International Journal of Advanced Manufacturing Technology. 2018; 97(9):3535-46.

[2] Brandl E, Heckenberger U, Holzinger V, Buchbinder D. Additive manufactured AlSi10Mg samples using selective laser melting (SLM): microstructure, high cycle fatigue, and fracture behavior. Materials & Design. 2012; 34:159-69.

[3] Kempen K, Thijs L, Yasa E, Badrossamay M, Verheecke W, Kruth JP. Process optimization and microstructural analysis for selective laser melting of AlSi10Mg. International solid freeform fabrication symposium 2011. University of Texas at Austin.

[4] Maamoun AH, Xue YF, Elbestawi MA, Veldhuis SC. Effect of selective laser melting process parameters on the quality of al alloy parts: powder characterization, density, surface roughness, and dimensional accuracy. Materials. 2018; 11(12):1-23.

[5] Mercelis P, Kruth JP. Residual stresses in selective laser sintering and selective laser melting. Rapid Prototyping Journal. 2006; 12(5):254-65.

[6] Dong Z, Xu M, Guo H, Fei X, Liu Y, Gong B, et al. Microstructural evolution and characterization of AlSi10Mg alloy manufactured by selective laser melting. Journal of Materials Research and Technology. 2022; 17:2343-54.

[7] Zhang C, Zhu H, Hu Z, Zhang L, Zeng X. A comparative study on single-laser and multi-laser selective laser melting AlSi10Mg: defects, microstructure and mechanical properties. Materials Science and Engineering: A. 2019; 746:416-23.

[8] Li W, Li S, Liu J, Zhang A, Zhou Y, Wei Q, et al. Effect of heat treatment on AlSi10Mg alloy fabricated by selective laser melting: microstructure evolution, mechanical properties and fracture mechanism. Materials Science and Engineering: A. 2016; 663:116-25.

[9] Yuan W, Chen H, Cheng T, Wei Q. Effects of laser scanning speeds on different states of the molten pool during selective laser melting: simulation and experiment. Materials & Design. 2020; 189:1-10.

[10] Huang M, Yang B, Zhou Y, Guan X, Wang Y, Liao Z, et al. Effect of processing parameters on tensile properties and microstructure of selective laser melted AlSi10Mg alloy. Journal of Materials Engineering and Performance. 2025; 34(7):6001-14.

[11] Liu YJ, Liu Z, Jiang Y, Wang GW, Yang Y, Zhang LC. Gradient in microstructure and mechanical property of selective laser melted AlSi10Mg. Journal of Alloys and Compounds. 2018; 735:1414-21.

[12] Beretta S, Gargourimotlagh M, Foletti S, Du PA, Riccio M. Fatigue strength assessment of “as built” AlSi10Mg manufactured by SLM with different build orientations. International Journal of Fatigue. 2020; 139:1-16.

[13] Trevisan F, Calignano F, Lorusso M, Pakkanen J, Aversa A, Ambrosio EP, et al. On the selective laser melting (SLM) of the AlSi10Mg alloy: process, microstructure, and mechanical properties. Materials. 2017; 10(1):1-23.

[14] Wu J, Wang L, An X. Numerical analysis of residual stress evolution of AlSi10Mg manufactured by selective laser melting. Optik. 2017; 137:65-78.

[15] Tradowsky U, White J, Ward RM, Read N, Reimers W, Attallah MM. Selective laser melting of AlSi10Mg: influence of post-processing on the microstructural and tensile properties development. Materials & Design. 2016; 105:212-22.

[16] Majeed A, Ahmed A, Salam A, Sheikh MZ. Surface quality improvement by parameters analysis, optimization and heat treatment of AlSi10Mg parts manufactured by SLM additive manufacturing. International Journal of Lightweight Materials and Manufacture. 2019; 2(4):288-95.

[17] Aboulkhair NT, Maskery I, Tuck C, Ashcroft I, Everitt NM. On the formation of AlSi10Mg single tracks and layers in selective laser melting: microstructure and nano-mechanical properties. Journal of Materials Processing Technology. 2016; 230:88-98.

[18] Sajin JSS, Mishra SK, Upadhyay RK. Effect of scanning strategy on the microstructure and load-bearing characteristics of additive manufactured parts. Journal of Manufacturing and Materials Processing. 2024; 8(4):1-14.

[19] Krasniqi M, Löffler F. Comprehensive effect of scanning strategy on the microstructure and load-bearing characteristics of additive manufactured in laser powder bed fusion. Discover Mechanical Engineering. 2024; 3(1):1-14.

[20] Gadlegaonkar N, Bansod PJ, Lakshmikanthan A, Bhole K. A review on additively manufactured AlSi10Mg alloy: mechanical, tribological, and microstructure properties. Journal of Mines, Metals & Fuels. 2025; 73(1):87-101.

[21] Boschetto A, Bottini L, Pilone D. Metallurgical defects and roughness investigation in the laser powder bed fusion multi-scanning strategy of AlSi10Mg parts. Metals. 2024; 14(6):1-17.

[22] Han M, Kaşıkcıoğlu S, Ergene B, Atlıhan G, Bolat Ç. An experimental investigation on the mechanical and wear responses of lightweight AlSi10Mg components produced by selective laser melting: effects of building direction and test force. Science of Sintering. 2025; 57(1):87-101.

[23] Tang P, Yan T, Wu Y, Tang H. Effect of deep cryogenic aging treatment on microstructure and mechanical properties of selective laser-melted AlSi10Mg alloy. Metals. 2024; 14(5):1-17.

[24] Cooke A, Slotwinski J. Properties of metal powders for additive manufacturing: a review of the state of the art of metal powder property testing. National Institute of Standards and Technology IR 7873. 2012.

[25] Yang P, Rodriguez MA, Deibler LA, Jared BH, Griego J, Kilgo A, et al. Effect of thermal annealing on microstructure evolution and mechanical behavior of an additive manufactured AlSi10Mg part. Journal of Materials Research. 2018; 33(12):1701-12.

[26] Aboulkhair NT, Everitt NM, Ashcroft I, Tuck C. Reducing porosity in AlSi10Mg parts processed by selective laser melting. Additive Manufacturing. 2014; 1:77-86.

[27] Kempen K, Thijs L, Van HJ, Kruth JP. Processing AlSi10Mg by selective laser melting: parameter optimisation and material characterisation. Materials Science and Technology. 2015; 31(8):917-23.

[28] Thijs L, Kempen K, Kruth JP, Van HJ. Fine-structured aluminium products with controllable texture by selective laser melting of pre-alloyed AlSi10Mg powder. Acta Materialia. 2013; 61(5):1809-19.

[29] Mauduit A, Pillot S, Frascati F. Application study of AlSi10Mg alloy by selective laser melting: physical and mechanical properties, microstructure, heat treatments and manufacturing of aluminium metallic matrix composite (MMC). Metallurgical Research & Technology. 2015; 112(6):1-23.

[30] Aboulkhair NT, Maskery I, Tuck C, Ashcroft I, Everitt N. Nano-hardness and microstructure of selective laser melted AlSi10Mg scan tracks. In industrial laser applications symposium (ILAS 2015) 2015. SPIE.

[31] Lam LP, Zhang DQ, Liu ZH, Chua CK. Phase analysis and microstructure characterisation of AlSi10Mg parts produced by selective laser melting. Virtual and Physical Prototyping. 2015; 10(4):207-15.

[32] Ding X, Wang L. Heat transfer and fluid flow of molten pool during selective laser melting of AlSi10Mg powder: simulation and experiment. Journal of Manufacturing Processes. 2017; 26:280-9.

[33] Takata N, Kodaira H, Suzuki A, Kobashi M. Size dependence of microstructure of AlSi10Mg alloy fabricated by selective laser melting. Materials Characterization. 2018; 143:18-26.

[34] Liu Y, Liu C, Liu W, Ma Y, Tang S, Liang C, et al. Optimization of parameters in laser powder deposition AlSi10Mg alloy using Taguchi method. Optics & Laser Technology. 2019; 111:470-80.

[35] Salmi A, Atzeni E. History of residual stresses during the production phases of AlSi10Mg parts processed by powder bed additive manufacturing technology. Virtual and Physical Prototyping. 2017; 12(2):153-60.

[36] Wei P, Wei Z, Chen Z, He Y, Du J. Thermal behavior in single track during selective laser melting of AlSi10Mg powder. Applied Physics A. 2017; 123(9):1-13.

[37] Palumbo B, Del RF, Martorelli M, Lanzotti A, Corrado P. Tensile properties characterization of AlSi10Mg parts produced by direct metal laser sintering via nested effects modeling. Materials. 2017; 10(2):1-16.

[38] Chen T, Wang L, Tan S. Effects of vacuum annealing treatment on microstructures and residual stress of AlSi10Mg parts produced by selective laser melting process. Modern Physics Letters B. 2016; 30(19):1650255.

[39] Jiang X, Xiong W, Wang L, Guo M, Ding Z. Heat treatment effects on microstructure-residual stress for selective laser melting AlSi10Mg. Materials science and Technology. 2020; 36(2):168-80.

[40] Fousová M, Dvorský D, Michalcová A, Vojtěch D. Changes in the microstructure and mechanical properties of additively manufactured AlSi10Mg alloy after exposure to elevated temperatures. Materials Characterization. 2018; 137:119-26.

[41] Yang Y, Zhu Y, Yang H. Enhancing wear resistance using selective laser melting (SLM): influence of scanning strategy. Jurnal Tribologi. 2019; 23:113-24.

[42] Maamoun AH, Elbestawi M, Dosbaeva GK, Veldhuis SC. Thermal post-processing of AlSi10Mg parts produced by selective laser melting using recycled powder. Additive Manufacturing. 2018; 21:234-47.

[43] Lv F, Shen L, Liang H, Xie D, Wang C, Tian Z. Mechanical properties of AlSi10Mg alloy fabricated by laser melting deposition and improvements via heat treatment. Optik. 2019; 179:8-18.

[44] Sajadi F, Tiemann JM, Bandari N, Cheloee DA, Mola J, Schmauder S. Fatigue improvement of AlSi10Mg fabricated by laser-based powder bed fusion through heat treatment. Metals. 2021; 11(5):1-17.

[45] Tang M, Pistorius PC, Narra S, Beuth JL. Rapid solidification: selective laser melting of AlSi10Mg. JOM. 2016; 68(3):960-6.

[46] Hovig EW, Azar AS, Mhamdi M, Sørby K. Mechanical properties of AlSi10Mg processed by laser powder bed fusion at elevated temperature. In TMS, 149th annual meeting & exhibition supplemental proceedings 2020 (pp. 395-404). Cham: Springer International Publishing.

[47] Weingarten C, Buchbinder D, Pirch N, Meiners W, Wissenbach K, Poprawe R. Formation and reduction of hydrogen porosity during selective laser melting of AlSi10Mg. Journal of Materials Processing Technology. 2015; 221:112-20.

[48] Larrosa NO, Wang W, Read N, Loretto MH, Evans C, Carr J, et al. Linking microstructure and processing defects to mechanical properties of selectively laser melted AlSi10Mg alloy. Theoretical and Applied Fracture Mechanics. 2018; 98:123-33.

[49] Biffi CA, Fiocchi J, Tuissi AJ. Selective laser melting of AlSi10 Mg: influence of process parameters on Mg2Si precipitation and Si spheroidization. Journal of Alloys and Compounds. 2018; 755:100-7.

[50] Amani Y, Dancette S, Delroisse P, Simar A, Maire E. Compression behavior of lattice structures produced by selective laser melting: X-ray tomography based experimental and finite element approaches. Acta Materialia. 2018; 159:395-407.

[51] Iturrioz A, Gil E, Petite MM, Garciandia F, Mancisidor AM, San SM. Selective laser melting of AlSi10Mg alloy: influence of heat treatment condition on mechanical properties and microstructure. Welding in the World. 2018; 62(4):885-92.

[52] Parveen S, Rao RS, Telasang G. Investigation on correlation between microstructure and mechanical properties of Alsi10Mg specimens by AM technology. The international conference on emerging trends in engineering 2021 (pp. 1-5).

[53] Mathe N. Influence of stress relieving thermal cycles on AISI10Mg specimens produced by selective laser melting. In conference series: materials science and engineering 2019 (pp. 1-7). IOP.

[54] Cerri E, Ghio E. AlSi10Mg alloy produced by selective laser melting: relationships between vickers microhardness, rockwell hardness and mechanical properties. International Journal of the Italian Association for Metallurgy. 2020; 112(7-8):5-17.

[55] Raju BS, Chandra SU, Drakshayani DN. Grey relational analysis coupled with principal component analysis for optimization of stereolithography process to enhance part quality. In IOP conference series: materials science and engineering 2017 (pp. 1-13). IOP Publishing.

[56] Rosenthal I, Stern A, Frage N. Microstructure and mechanical properties of AlSi10Mg parts produced by the laser beam additive manufacturing (AM) technology. Metallography, Microstructure, and Analysis. 2014; 3(6):448-53.

[57] Dong Z, Liu Y, Li W, Liang J. Orientation dependency for microstructure, geometric accuracy and mechanical properties of selective laser melting AlSi10Mg lattices. Journal of Alloys and Compounds. 2019; 791:490-500.

[58] Aboulkhair NT, Stephens A, Maskery I, Tuck C, Ashcroft I, Everitt NM. Mechanical properties of selective laser melted AlSi10Mg: nano, micro, and macro properties. International solid freeform fabrication symposium 2015. University of Texas at Austin.