Abstract

As additive techniques such as laser powder bed fusion find increasing adoption industry, the ability to adapt these processes to industrially relevant materials is paramount. This adaptation can represent a significant challenge when working with wrought alloy feedstocks, which often result in brittle or porous parts lacking the mechanical properties of their conventionally wrought counterparts. One such alloy, aluminium 6061, is a highly used alloy in the aerospace, automotive, and semiconductor manufacturing industries. The conventionally manufactured components can have complex morphologies and may be assemblies of multiple individual components. As such, the ability to use an additive approach, and produce these as single parts can lead to significant benefits. In this work, we examine laser powder bed fusion of aluminium alloy 6061. The effects of process parameters such as laser power, beam scan speed, hatching distance, spot size was examined with a view towards developing an optimised process for this traditionally wrought alloy. Parts were examined for porosity and microstructure, with an aim to develop greater than 95% relative densities. To aid in process optimisation, in-situ pyrometry was deployed to understand the effects of the process parameters and develop a robust and repeatable process for producing 6061 components.