Correlation of Energy Density and Manufacturing Variables of AA6061 through Laser Powder Bed Fusion and Its Effect on the Densification Mechanism

Aluminum alloy processing via additive manufacturing (AM) technologies has increased in usage during the last decade. AM now enables manufacturing complex geometries not previously achieved through traditional manufacturing. Aluminum is usually processed using laser powder bed fusion (LPBF) technologies, which are used to manufacture metallic components of high geometrical complexity and dimensional accuracy and good mechanical, electrical, and chemical properties, which is why this technology is quite popular at industrial levels. To further develop quality control systems and new aluminum alloys using LPBF, there is a need to establish a predictive relationship between the parameters of the material. A study was carried out to investigate the relationship between energy density and process parameters such as laser power, scan speed, hatch spacing, scan pattern, and laser focus and its influence on the densification mechanism in additively manufactured components with aluminum alloys. AA6061 was selected due to its wide usage in different industries, given its low density and high mechanical performance. Relative density was analyzed using the Archimedes principle, and the quality and morphology of the AA6061 powder were analyzed through metallographic analysis. The process parameter selection was performed according to the best results obtained according to the laser power and energy density factors. The best manufactured samples had an energy density between 30 and 40 J/mm3, with relative densities above 99%.