Thin Wall and Overhanging Structures of Aluminum Alloy Fabricated by Selective Laser Melting

Selective laser melting (SLM) technology is based on the principle of "discrete+stacking", using high-energy laser beam as heat source to melt metal powders, and directly forming structural components with complex spatial configurations and excellent performance through layer by layer stacking. In this study, the formability and design principles of typical geometric shapes of AlSi10Mg alloys prepared by SLM process are analyzed, and based on the pre-optimized process parameters, pipe channel structure, overhanging structure inclination angle and thin-walled structure are fabricated. The research results indicate that the aperture forming design range of the pipe channel structure is ø3-10 mm, and that the forming size of the thin-walled part should not be less than 0.20 mm. If the inclination angle of the overhanging structure is less than 45°, the hanging part will collapse and hang slag. The research results can achieve high-precision design and manufacturing of thin-walled and overhanging structural components, providing theoretical guidance for industrial production applications.