Effect of energy density on down surface characteristics of AlSi10Mg alloy fabricated via selective laser melting

The correlation between surface roughness and energy density in the down surface area of AlSi10Mg alloy manufactured by selective laser melting was analyzed. This study investigated the relationship between the contour melt pool shape and surface roughness in the down surface area across an energy density range of 10-150 J/mm³. As the energy density increased, the contour melt pool in the down surface area became more stable, which significantly influenced surface roughness. Low energy density resulted in the unstable formation of the contour melt pool, leading to a deterioration in surface quality, whereas high energy density promoted the stable formation of the melt pool. Sufficient energy density is essential for the complete formation of the contour melt pool on the down surface, which plays a crucial role in reducing surface roughness. However, within the energy density range where the contour melt pool is fully formed, keyhole defects may occur, and it can be anticipated that these defects may worsen at energy densities exceeding the critical threshold.