Materials: Mechanical Properties of SLM-Printed Aluminium Alloys: A Review

materials
Review
Mechanical Properties of SLM-Printed Aluminium
Alloys: A Review
Panneer Ponnusamy 1,2 , Rizwan Abdul Rahman Rashid 1,2, * , Syed Hasan Masood 1,2 ,
Dong Ruan 1,2 and Suresh Palanisamy 1,2
1 Faculty of Science, Engineering and Technology, Swinburne University of Technology,
Hawthorn, VIC 3122, Australia; [email protected] (P.P.); [email protected] (S.H.M.);
[email protected] (D.R.); [email protected] (S.P.)
2 Defence Materials Technology Centre (DMTC) Limited, Hawthorn, VIC 3122, Australia
* Correspondence: [email protected]

Received: 30 July 2020; Accepted: 23 September 2020; Published: 26 September 2020
Abstract: Selective laser melting (SLM) is a powder bed fusion type metal additive manufacturing
process which is being applied to manufacture highly customised and value-added parts in biomedical,
defence, aerospace, and automotive industries. Aluminium alloy is one of the widely used metals
in manufacturing parts in SLM in these sectors due to its light weight, high strength, and corrosion
resistance properties. Parts used in such applications can be subjected to severe dynamic loadings and
high temperature conditions in service. It is important to understand the mechanical response of such
products produced by SLM under different loading and operating conditions. This paper presents a
comprehensive review of the latest research carried out in understanding the mechanical properties
of aluminium alloys processed by SLM under static, dynamic, different build orientations, and heat
treatment conditions with the aim of identifying research gaps and future research directions.
Keywords: selective laser melting; aluminium alloys; mechanical properties; tensile; compression;
fatigue; heat treatment; build orientation
1. Introduction
Additive manufacturing (AM), more popularly known as 3D printing (3DP), has been extensively
applied for various engineering applications. When compared to conventional manufacturing,
highly complex parts such as lattice structures can be produced by AM because of the layer-by-layer
fabrication process [1]. In recent times, AM technologies are being sought after for providing customized
solutions to problems arising due to the COVID-19 virus [2]. Several technologies are in practice
for the AM of metallic parts, which include selective laser melting (SLM), electron beam melting
(EBM), laser engineered net shaping (LENS), direct metal deposition (DMD), and cold spray additive
manufacturing (CSAM). Each of these processes offers its own merits and limitations in terms of quality
of the print-part, mechanical property, performance of the component, and the range of materials
that can be fabricated. Among these AM processes, SLM is being widely accepted by industry to
manufacture customized, high value-added, and complex metal components for aerospace, automotive,
defence, and biomedical applications [3]. SLM is a powder-bed fusion type process that produces
metal parts by selectively fusing metal powders on a platform using a laser beam. Figure 1 presents the
schematic illustration of the SLM process. According to Kempen et al. [4], the fusing occurs through
the melting and rapid solidification of metal powders scanned by a laser beam along a 3D print-path
created by a processing software.
Materials 2020, 13, 4301; doi:10.3390/ma13194301 www.mdpi.com/journal/materials

Materials 2020, 13, 4301 2 of 51
Materials 2020, 13, x FOR PEER REVIEW 2 of 68
Figure 1.
Figure 1. Illustration
Illustration of
of the
the SLM process [5].
SLM process [5].
Aluminiumalloys,
Aluminium alloys, titanium
titanium alloys,
alloys, steelssteels including
including stainless stainless
steels and steels and tool
tool steels, steels,
nickel nickel
superalloys,
superalloys,
and and cobalt-chromium
cobalt-chromium alloys are the most alloyscommon
are the SLM-processed
most common metals. SLM-processed
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are comparable
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a lot ofprocess
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understanding the at understanding
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mechanical properties, on performance,
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main process of the
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main process
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in SLM areandthe properties
laser power, in hatch
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powder layer thickness, scan speed, and scan strategy. Maamoun et al. [6] presented a detailed scan strategy. Maamoun et al. [6]
presented
study on thea influence
detailed study
of these onprocessing
the influence of these
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relative density,parameters
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relative density,
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properties.
and properties.
Aluminium (Al) and its alloys are characterized by their light weight, high strength, corrosion
Aluminium
resistance, and good (Al)weldability,
and its alloys are characterized
making them suitablebyfor their lightof
a range weight, high strength,
applications corrosion
in industries such
resistance,
as and good
automotive, weldability,
aerospace, machinerymaking andthem suitable
tooling, for aand
defence, range of applications
construction. Of the in industries such
different alloy
as automotive,aluminium-silicon-based
combinations, aerospace, machinery and tooling,
alloys (Al-Si), defence, and AlSi
specifically construction.
10 Mg, AlSi Of
12 , the
A356 different
(AlSi 7 Mgalloy
0.3 ),
combinations, aluminium-silicon-based alloys (Al-Si), specifically AlSi
and A357 (AlSi7 Mg0.7 ), have been extensively used in the SLM process owing to their fabricability.0.3),
10 Mg, AlSi 12 , A356 (AlSi 7 Mg
and A357 (AlSi7presents
This paper Mg0.7), have been extensively
a comprehensive review usedon in theresearch
latest SLM process owingontomechanical
conducted their fabricability.
properties
of Al This
alloyspaper presents
processed by SLM. a comprehensive
A large number review of articles onhave
latestbeenresearch
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on process onoptimization,
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anisotropy Al alloys
effects due toprocessed by SLM. A
build orientation, large
and thenumber
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paper presents effectsa classification
due to build and orientation,
discussion and ofthe improvement
these published papers of SLM built
into part
various
properties by heat treatment. This paper presents a classification and discussion
research categories to identify research directions and research gaps for different types of mechanical of these published
papers intoand
properties various researchunder
performance categories
statictoand
identify
dynamic research
loadingdirections and research gaps for different
conditions.
types of mechanical properties and performance under static and dynamic loading conditions.
2. 3D-Printing of Aluminium Alloys by SLM
Aluminium alloys processed by SLM are attracting attention due to their light weight, high strength
to weight ratio, corrosion resistance, and good mechanical properties, and due to the unique advantages
offered by SLM, such as tool-less fabrication, geometric freedom, customized design, and intricate
shapes. As a result, there is an increased interest from researchers to fabricate Al-Si alloy components
using SLM with desirable properties.
Even though Al-Si alloys find extensive applications in the cast form, they are difficult to
process using SLM because it is a laser-based process with rapid melting and solidification. Al
Materials 2020, 13, 4301 3 of 51
powders are lightweight, have poor flowability, high reflectivity, and high thermal conductivity.
Moreover, Al powders have low laser absorption and are prone to oxidation and balling [8].
Montero-Sistiaga et al. [9] have stated that, besides high reflectivity, high reactivity with oxygen, and high
conductivity, there are potential challenges in processing Al alloys using SLM. Despite these drawbacks,
aluminium can be alloyed with other metals to overcome some of these challenges. Therefore, the two
most common Al-Si alloys used in SLM systems are AlSi10 Mg and AlSi12 . The addition of silicon to
aluminum improves its fluidity and reduces its melting temperature. The addition of magnesium to
aluminum increases its strength through solid solution strengthening and also improves its strain
hardening ability [10]. Although significant amount of works are published on AlSi10 Mg, the research
work on AlSi12 and other Al-Si alloys, including A356 and A357, is still evolving [11–26].
Table 1 presents a compilation of key published literature on the SLM of these Al alloys, which are
reviewed in detail in this study, capturing the main findings of each article, considering the process
conditions (build orientation, heat treatment, and process optimisation), types of mechanical properties,
and type of SLM machine used. It was also noted that most of the researchers have used commercial
SLM machines produced by leading SLM manufacturers, such as SLM Solutions, EOS, Concept Laser,
Realizer, and Renishaw. More detailed discussion on some of these publications is presented in later
sections of this review.
Materials 2020, 13, 4301 4 of 51
Table 1. List of published literature on SLM of aluminium alloys.
Mechanical Properties
Author (Year) Material Process Conditions Main Findings SLM Machine Reference
Evaluated
• At lower stress levels, machining the samples
Laser power 200 W, layer thickness improved the fatigue performance, but did not
25 µm, scan speed 550 mm/s, hatch have any influence at higher stress levels.
spacing 80 µm, and scan strategy • Heat treating the samples significantly improved
Aboulkhair et al. chess board. the fatigue life, and it was found that at 94 MPa
AlSi10 Mg Fatigue Renishaw AM250 [27]
(2016) Heat treatment: Solution treated at stress loading, the heat-treated samples
520 ◦ C for 1 h, water quenched to outperformed their cast counterparts in terms of
room temperature and then fatigue life.
aged for 6 h at 160 ◦ C. • The samples that were heat-treated and machined
showed the best fatigue performance.
• The printed parts had tensile strength better than
the diecast parts.
Laser power 200 W, scan speed • After heat treatment, the hardness and the tensile
550 mm/s, hatch spacing 130 µm, Tensile strength, strength of the printed parts reduced by about
Aboulkhair et al. 20% and 12%, respectively, whereas the ductility
AlSi10 Mg layer thickness 25 µm, compressive yield strength, Renishaw AM250 [11]
(2016) increased by a factor of 2.8.
and checkerboard scan strategy. nano-hardness
Heat treatment: T6 • The compressive yield strength of the heat-treated
parts was 169 ± 6 MPa which was approximately
half the strength of the as-built parts.
• Uniform nano-hardness of 1.82 ± 0.01 GPa was
observed in the SLMed samples due to the
Laser power 200 W, point distance homogeneous distribution of Si particles
80 µm, exposure time 140 µs, hatch segregating at α-Al grain boundaries.
Aboulkhair et al. Tensile and compressive
AlSi10 Mg spacing 130 µm, layer thickness Renishaw AM250 [12]
(2015) strength, nano-hardness • Microhardness along the plane parallel to the
25 µm and checkerboard scan
build plane was found to be higher (109.7 ± 0.9
strategy.
HV) than the plane perpendicular to the build
plane (99.07 ± 2 HV).
• The nano-hardness of the heat-treated samples
(1.56 ± 0.11 GPa) was reduced by 42% compared
Two 400 W lasers at CalRAM Inc. to the strength of the as-built samples
were used, with default SLM 280 (2.71 ± 0.12 GPa).
parameter set. • Heat treatment of the samples resulted in the 400 W laser at
Alghamdi and
AlSi10 Mg Heat Treatment: T6, solutionising at Nano-hardness change in microstructure from cellular grains to CalRAM Inc. [28]
Haghshenas (2019)
520 ◦ C for 1 h, followed by water fragmented/spheroidised eutectic silicon particles. SLM 280
quench, then artificial ageing at • The effect of the indentation size was observed in
170 ◦ C for 4 h. both as-built and heat-treated samples. With the
decrease in the depth of indent, the
hardness increased.
Materials 2020, 13, 4301 5 of 51
Table 1. Cont.
Evaluated
• Deformation behaviour of two face-centred cubic
lattice structures with thin and thick struts was
studied using both in-situ and ex-situ X-ray
Laser power 250 W, scanning speed computed tomography technique.
Amani et al. (2018) AlSi10 Mg 571 mm/s, layer thickness 60 µm, Compression behaviour • A finite element model was developed using SLM 250 [29]
and argon gas atmosphere. Gurson-Tvergaard-Needleman (GTN) porous
plasticity model.
• Simulations showed a fairly good agreement with
the model’s prediction of fracture location.
• The quality of the as-built samples depended
upon the velocity of the gas flow in the built
chamber, the direction of laser scan with respect to
the gas flow direction, and position of the part
with respect to the chamber outlet location.
Laser power 350 W, layer thickness
• Higher ultimate tensile strength (UTS) values for
Anwar & Pham (2017) AlSi10 Mg 100 µm, laser speed 900 mm/s, Tensile strength SLM Solutions 280 HL [30]
parts printed with laser scan direction against the
and hatch spacing of 0.12 mm. gas flow, with higher gas velocity, and closer to
the outlet was observed.
• When the laser scanning was in the direction of
gas flow, a reduced accumulation of spatter
powder particles was observed near the outlet.
• Increasing the strain rate from 150 s−1 to 1600 s−1

Laser power 370 W, scanning speed resulted in higher yield, peak flow stress,
1300 mm/s, hatch distance 190 µm, and ductility.
powder layer thickness 30 µm, build Dynamic compression,
• The texture evolution could be attributed to
Asgari et al. (2018) AlSi10 Mg platform pre-heating temperature Split Hopkinson pressure EOS M290 machine [31]
vertical build orientation than horizontal build
200 ◦ C. bar testing
orientation due to uniform and dense
Build orientation: Vertical and
microstructure, while the texture is not affected by
Horizontal.
the deformation at high strain rates.
• Effect of build plate heating on the tensile
properties was evaluated and build plate heating
temperatures of 140 ◦ C and 170 ◦ C were reported
to yield highest tensile strength of 408 ± 5 MPa
Laser power 195 W, scan speed and a yield strength of 284 ± 3 MPa.
1200 mm/s, layer thickness 30 µm, • The platform heating induces artificial ageing EOS M270 Dual Mode
Aversa et al. (2017) A357 Tensile [32]
hatching distance 0.1 mm and stripe within the print-parts during processing. system
scanning strategy.
• Low platform heating temperatures result in
under-ageing whereas high platform heating
temperatures result in over-ageing of the
printed samples.
Materials 2020, 13, 4301 6 of 51
Table 1. Cont.
Evaluated
• The pore density of 90◦ built samples were seven
times higher than the 0◦ built samples.
Process parameters not disclosed. • The 0◦ built samples displayed 8% higher tensile
Awd et al. (2018) AlSi10 Mg Build orientation: 0◦ , 45◦ and 90◦ Tensile strength than the samples built at 90◦ orientation. M2 Cusing system [33]
with respect to the build plate.
• Samples fabricated along the 45◦ orientation had a
significantly reduced fracture strain.
• Using the optimised process parameters, a relative
density > 99% was achieved.
Laser power 200 W, layer thickness • The AlSi12 powder with good flowability and
50 µm, stripe hatch scanning strategy, apparent density leads to good processability in
Baitimerov et al. Sinterstation® Pro
AlSi12 powder dried at 100 ◦ C for 1 h and Density SLM, while highly fine and spherically shaped [34]
(2018) powder particles result in poor processability. DM125 SLM System
the oxygen inside the build chamber
was maintained below 500 ppm. • The particles with nearly spherical shaped
morphology exhibited very poor flowability,
leading to high porosity levels.
• The cyclic plasticity occurs when the longitudinal
strain exceeds 0.9.
Laser power ranging 360 W–400 W, • The failure of the printed parts was attributed to
layer thickness 0.05 mm, laser the presence of large density of
Bao et al. (2020) AlSi10 Mg scanning speed Fatigue secondary micro-voids. BLT S310 [35]
1200 mm/s–1500 mm/s, scan spacing
• The elongation of original defects along the
0.13–0.16 mm.
loading direction is 10 times faster than that along
the lateral side.
Laser power 950 W, scan speed
2000 mm/s, spot size 400 µm, hatch • A 0.2% proof stress of 192 ± 17 MPa was found for
distance 0.2 mm, layer thickness as-built A357 samples built in the X Line 2000R
Bassoli et al. (2018) A357 Tensile, Fatigue vertical orientation. [36]
50 µm, nitrogen gas chamber (Concept Laser)
atmosphere, preheating temperature • A fatigue strength of 60 ± 5.3 MPa was obtained.
200 ◦ C and skin core scan strategy.
• Moderate correlation between the surface features
at the origin of the fracture and surface roughness
Laser power 350 W, hatch distance of the printed parts was found.
0.13 mm, scan speed 1650 mm/s, • Horizontal-built specimens had highest fatigue
layer thickness 50 µm, preheating of strength compared to inclined- and
Beretta et al. (2020) AlSi10 Mg Fatigue strength SLM 280HL v1.0 [37]
build platform up to 150 ◦ C. vertical-built specimens.
Build orientation: Horizontal (0◦ ), • EIFS and fatigue life prediction models were
Inclined (45◦ ), and Vertical (90◦ ). developed and verified using experimental data.
The estimated cycles to failure was found within
factor of 0.5–2 of the experimental values.
Materials 2020, 13, 4301 7 of 51
Table 1. Cont.
Evaluated
Pulsed wave laser: laser power 300
W, build platform temperature • The continuous wave (CW) and pulsed wave
170 ◦ C, exposure time 120 µs, point (PW) showed similar Si network, however they
distance 130 µm, spot size 130 µm, varied in liquid melt pool. The continuous wave
hatch distance 140 µm, layer yielded better strength in compression, which Renishaw AM 250
thickness 25 µm and build chamber resulted in reduced influence of the sample build system
Biffi et al. (2018) AlSi10 Mg environment argon. Compression orientation on compression behaviour. [38]
SLM Solutions SLM
Continuous wave laser: laser power • The samples built with CW laser emission was 500 system
350 W, build platform temperature found to have better compressive strength than
150 ◦ C, laser travel speed 1150 mm/s, those processed with PW.
spot size 80 µm, hatch distance
• The anisotropy is better exhibited in PW than CW.
170 µm, layer thickness 50 µm and
build environment argon.
• Surface roughness prediction model that
incorporates the staircase effect and defects arising
due to satellites particles in the feedstock powder
Laser power 370 W, scan speed and the balling effect was developed.
1300 mm/s, hatch spacing 190 µm,
Boschetto et al. (2017) AlSi10 Mg Roughness • A case study on the surface roughness of a Pelton EOSINT® M290 [39]
layer thickness 30 µm, laser beam
bucket was carried out, comparing the
diameter 100 µm, hatch rotation 67◦ .
experimental values of surface roughness of
curved complex surfaces to that of the model
predicted data.
• Post heat treatment was found to have the most
Laser power 250 W, beam diameter considerable effect, whereas the build orientation
0.2 mm, layer thickness 50 µm, was found to have the least considerable effect on
scanning speed 500 mm/s, scan fatigue resistance.
• Heating the build plate to 300 ◦ C tended to Trumpf TrumaForm
spacing 0.15 mm and argon gas Fatigue (using tensile
Brandl et al. (2012) AlSi10 Mg neutralize the anistotropy effects due to build LF130 powder-bed [40]
shielding, with and without build samples), fracture analysis
orientation of the samples as well as enhanced the machine
plate heating, build plate heating
temperature 300 ◦ C. fatigue resistance.
Build orientation: 0◦ , 45◦ , and 90◦ . • The fatigue limit and the static tensile strength
significantly correlate with each other.
• Distortions in part geometry reduced from 10.6
mm to nearly zero after preheating at 250 °C.
Laser power 195 W, layer thickness • Reduction in hardness along with better resistance
30 µm, scanning speed 800 mm/s, to crack growth was observed when the build
Buchbinder et al.
AlSi10 Mg hatch distance 150 µm, hatch rotation Distortion plate was preheated. EOSINT M 270 [41]
(2013)
67◦ , preheating temperatures 100◦ ,
• With preheating, lower temperature gradient
150◦ , 200◦ , and 250◦ .
results in lower thermal stresses in the
printed parts.
Materials 2020, 13, 4301 8 of 51
Table 1. Cont.
Evaluated
• Ageing of parts printed on cold-platform resulted
Laser power 340 W, hatch distance in higher hardness and tensile strength compared
0.2 mm, scan rate 1300 mm/s, layer to hot-platform printed and aged parts. EOS M290 SLM
Casati et al. (2018) AlSi10 Mg Tensile [42]
thickness 30 µm, platform system
• The standard T6 temper heat treatment resulted in
temperature 160 ◦ C.
higher ductility but lower mechanical strength.
• The samples built under both argon and nitrogen
exhibited similarity in defect structure,
microstructure and nearly isotropic behaviour in
mechanical properties.
Laser power 370 W, scan speed • In the vertical orientation under nitrogen
1300 mm/s, hatch spacing 0.19 mm, atmosphere, samples exhibited tensile strength of
Tensile, surface roughness,
layer thickness 30 µm, preheating up 385 ± 5 MPa, whereas, at horizontal orientation
Ch et al. (2019) AlSi10 Mg porosity, fracture EOS M280 machine [43]
to 300 ◦ C. under argon atmosphere, samples exhibited the
morphology
Build orientation: Horizontal and lowest strength of 338 ± 2 MPa.
Vertical.
• The meso-structure and microstructure of the
material revealed the characteristic nature of
SLMed AlSi10 Mg alloy which contains melt pool
tracks, columnar grains and cellular structure.
• Orowan looping leads to high strength and high
Laser power 350 W, scan speed strain hardening capability. SLM 250HL, SLM
Chen et al. (2017) AlSi10 Mg 1170 mm/s, layer thickness 50 µm, Tensile [44]
• The hierarchical structure yields high yield Solutions
hatch spacing 240 µm.
strength of 300 MPa and UTS of 455 MPa.
• Using pulsed laser for printing was demonstrated
Laser power 0.5–4.5 kW, travel speed wherein Si refinement to size below 200 nm
90–180 mm/min, spot size 150 µm, was achieved. In house built
Chou et al. (2015) AlSi12 Hardness, density [45]
hatch distance 0.1 mm, layer Pulsed-SLM facility
• The print part density was 95% and hardness was
thickness 0.1 mm.
135 HV when using pulsed laser for fabrication.
• Dense parts (98 ± 0.4%) were fabricated using
Laser power (peak) 5 kW, square customized pulsed laser SLM system.
pulse, hatch distance 0.1 mm, layer • Hunt’s criterion predicted primarily a columnar
A356 In house built
Chou et al. (2018) thickness 100 µm, bidirectional Density grain structure throughout the pulsed laser [21]
(AlSi7 Mg0.3 ) Pulsed-SLM facility
zigzag scanning pattern, argon printed parts which was confirmed through
atmosphere. electron backscatter diffraction
(EBSD) observations.
Materials 2020, 13, 4301 9 of 51
Table 1. Cont.
Evaluated
• The oxidation played a significant role in the melt
pool dynamics with thermo-capillary convection
Laser power 180 W, scan speed 100, where convection took place from inward to
Numerical simulation,
AlSi10 Mg 200, 300, and 400 mm/s, laser energy outward flow pattern.
Dai and Gu (2016) thermodynamics of the In house SLM [46]
composite per unit length (LEPUL) 450, 600,
molten pool • The thermocapillary flow yields a driving force
900, and 1800 J/m.
for the migration and rearrangement of
reinforcing particles in the melt pool.
• The wear resistance was significantly influenced
Laser power 200 W, layer thickness by the densification rate, distribution state and the
AlSi10 Mg 30 µm, scanning speed powder particle size.
Dai et al. (2018) Wear In house SLM [47]
composite 100–300 mm/s, hatch spacing • Lowest wear rate of 3.4 × 10−4 mm3 N−1 m−1 was
60–100 µm. found when using an optimised laser volume
energy density of 420 J/mm3 .
• The yield strength of the horizontal-built samples
was considerably greater than that of the
vertical-built samples.
Laser power 200 W, layer thickness • The yield strength of the samples in artificially
de Menezes et al. aged condition was greater than the Renishaw AM250
A357 25 µm, hatch distance 115 µm. Tensile [48]
(2019) SLM system
Isothermal aging at 160 ◦ C for 4 h. as-built condition.
• A crack orthogonal to the building orientation
results in a significant decrease in fracture
toughness of the printed samples.
• The fracture likely occurs in the heat-affected zone
(HAZ) region due to the presence of coarse
non-coherent Si precipitates.
Laser power 175 W, scan speed • The intercellular network of eutectic structure is
Nanohardness, fracture partially broken in the HAZ regions, thereby
Delahaye et al. (2019) AlSi10 Mg 195 mm/s, layer thickness 60 µm, MTT SLM 250 [49]
morphology, tensile
preheating temperature 200 ◦ C. facilitating dislocation slip and plastic
strain localisation.
• The cells size of the HAZ was found to match with
the size of the dimples on the fracture surfaces.
Laser power 250 W, scan speed • Large levels of porosity and heterogenous
571 mm/s, layer thickness 60 µm, microstructure was observed in inclined strut.
and argon atmosphere. • Amount of hydrogen detected in the samples was
Deleroisse et al.
AlSi10 Mg Heat treatment: T6 heat treatment, Porosity, strut properties larger than the hydrogen solubility in the liquid - [50]
(2017)
annealing at 525 ◦ C for 5 h, water melt pool.
quench and then artificial ageing at • Heat treatment suppresses
165 ◦ C for 7 h. microstructural heterogeneities.
Materials 2020, 13, 4301 10 of 51
Table 1. Cont.
Evaluated
• Yield strength (195 ± 17 MPa) and modulus
Laser power 950 W, scanning speed (77.8 ± 6.8 GPa) were found to be maximum at 45◦
2000 mm/s, hatch distance 0.2 mm, inclined samples.
Concept Laser X Line
Denti (2018) A357 laser spot 400 µm, nitrogen chamber Shear, Tensile • The ultimate tensile strength and shear strength of [51]
2000 R
atmosphere, preheated at 200 ◦ C and vertical-built samples were found to be the
skin-core scan strategy. highest, 305 ± 15 MPa and
192 ± 9 MPa, respectively.
• There is negligible effect of exposure time on heat
Laser power 400 W, laser beam transfer, fluid flow, and melt pool dimension.
Modelling and simulation,
Ding and Wang (2017) AlSi10 Mg radius 67.5 µm, hatch space 130 µm, • The simulated temperature and melt pool - [52]
density, hardness
scan speed 300 mm/s. dimensions increase with an increase in
point distance.
• The size effect has a significant influence on the
geometric imperfection for SLM-processed
Laser power 370 W, laser spot size AlSi10 Mg strut.
100 µm, hatch spacing 190 µm, • The porosity level of the sample decreased from
Tensile, porosity, 1.87% to 0.1% with the variation of build size from Concept X-line 1000R
Dong et al. (2018) AlSi10 Mg scanning speed 1500 mm/s, layer [53]
fractography machine
thickness 30 µm, argon chamber 1 mm to 5 mm.
atmosphere. • The overall strength and modulus decreased by
approximately 30% with decrease in the build size.
• Chemical composition mapping and

nano-indentation showed higher hardness in the
Laser power 100 W, scan speed SLM material compared to its cast counterpart.
Everitt et al. (2016) AlSi10 Mg 250 mm/s, hatch space 50 µm, argon Nanohardness Realizer SLM-50 [54]
• The printed samples exhibited a nanohardness of
atmosphere.
9 ± 1 GPa, compared to 0.97 ± 1 GPa for the
cast samples.
• The samples demonstrated yield and tensile
Fracture surface strengths of about 102 MPa and 425 MPa,
Fefelov et al. (2017) AlSi12 - EOSINT M 280 device [55]
morphology, tensile respectively, along with fracture strain of 12%.
• The impact of preheating on tensile strength in x/y
Laser power 1000 W, layer thickness plane seems to be more pronounced than the
of 50 µm, volume energy 40 J/mm3 , impact of beam deflection. X LINE 2000R
Fiegl et al. (2019) AlSi10 Mg Tensile [56]
island scanning strategy and • UTS was found to be higher without preheating, (modified)
nitrogen atmosphere. 377 ± 16 MPa, compared to samples printed with
preheating strategy, 355 ± 15 MPa.
Materials 2020, 13, 4301 11 of 51
Table 1. Cont.
Evaluated
• Two exothermic phenomena involving Mg2 Si
Laser power 300 W, spot size 130 µm, precipitation and Si diffusion were found.
Differential scanning
Fiocchi et al. (2017) AlSi10 Mg layer thickness 25 µm, hatch distance Renishaw AM250 [57]
calorimetry, hardness • Isothermal transformation temperatures were identified
140 µm, and argon atmosphere.
to be 263 ◦ C and 294 ◦ C.
• Printed samples subjected to elevated temperatures
Laser power 350 W, layer thickness underwent microstructural and mechanical
50 µm, scanning speed 500 mm/s, property changes. SLM Solution 280HL
Fousova et al. (2018) AlSi10 Mg hatch spacing 170 µm, argon Tensile [58]
• At the tested temperature of 160 ◦ C, a slight increase in machine
atmosphere and chessboard
tensile yield strength (by 5%) but also a strong reduction
scanning strategy.
in elongation (by 60%) were observed.
• The as-built samples exhibited a yield strength of
Laser power 320 W, scan speed 240 ± 1 MPa and UTS of 385 ± 4 MPa.
Gokuldoss 1455 mm/s, layer thickness 50 µm, • After annealing at 300 ◦ C, the yield strength and UTS
AlSi12 Tensile SLM 250 HL [18]
Prashanth et al. (2016) hatch spacing 110 µm and argon reduced to 138 ± 3 MPa and 205 ± 5 MPa, respectively.
atmosphere. • The softening behaviour of the Al matrix was inversely
proportional to strain hardening behaviour.
• The fracture in the horizontal samples propagated along
the hatch overlap regions whereas in the vertical samples
Laser power 400 W, beam diameter the crack propagation was primarily along the
100 µm, argon atmosphere. inter-layer regions.
Build orientation: Horizontal and
Impact properties, fracture • The building orientation has a significant influence on the
Girelli et al. (2019) AlSi10 Mg Vertical properties of the printed samples even after post heat EOS M290 system [59]
morphology
Heat treatment: Solutionising at treatment is applied.
540 ◦ C for 1–9 h, followed by ageing
• After hot isostatic pressing the samples, the porosity
at 160 ◦ C for 4 h or 180 ◦ C for 2 h.
reduced considerably, and the fracture toughness of the
specimens improved.
• The mechanical properties of AlSi10 Mg parts produced by
Gong et al. (2017) AlSi10 Mg - Tensile SLM are much higher than the alloy formed by - [60]
conventional casting.
• Columnar cellular structure was observed in the
horizontal-built samples, whereas equiaxed structure was
Laser power 370 W, beam spot size observed in the vertical-built samples.
100 µm, scanning speed 1300 mm/s, • The dislocation density in the as-built horizontal and
Hadadzadeh et al. hatch spacing 190 µm, layer
AlSi10 Mg Dynamic compression vertical samples was 1.14 × 1014 m−2 and EOS M290 machine [61]
(2018) thickness 30 µm, argon atmosphere.
3.05 × 1014 m−2 , respectively.
• These dislocation networks converted to low angle grain
Vertical.
boundaries through dynamic recovery process to reduce
the energy, thereby resulting in softening of the samples.
Materials 2020, 13, 4301 12 of 51
Table 1. Cont.
Evaluated
• The samples exhibited strain hardening at strain rates
lower than 1400 s−1 , and at higher strain rates they
displayed double peak flow stress deformation regime.
Laser power 370 W, scanning speed
• Strengthening mechanisms included Hall-Petch
Hadadzadeh et al. 1300 mm/s, hatch spacing 190 µm, layer
AlSi10 Mg Dynamic compression contributed by cell walls, Orowon contributed by Si EOS M290 [62]
(2019) thickness 30 µm, stripe scanning
precipitates, and dislocation hardening.
strategy, argon atmosphere.
• Both cell walls and Si precipitates contribute to impeding
the dislocation motion and development of
dislocation networks.
Laser power 200 W, hatch spacing
130 µm, layer thickness 25 µm, scanning • The surface roughness of the laser surface remelted
speed 500 mm/s, chessboard samples was significantly reduced (0.93 µm) compared to
bidirectional scanning strategy. the as-built samples (19.3 µm).
Heat treatment: Solution-treated at • The yield strength reduced from 200 MPa in the as-built
Tensile, Hardness,
Han and Jiao (2019) AlSi10 Mg 550 ◦ C for 2 h, followed by furnace samples to 100 MPa in the heat-treated samples. Renishaw AM250 [63]
Roughness
cooling.
• The laser surface remelting process improved the
Laser surface remelting treatment: Laser
microhardness by 19.5% through refining
power 20 W, beam diameter 32 µm,
the microstructure.
scanning speed 300 mm/s, layer
thickness 0.01 mm.
• Laser shock peening induced tensile residual stresses
◦C Finite element analysis, within certain regions of the samples.
Heat treated at 170 for 3 h.
Hatamleh et al. (2018) A357 residual stress analysis, • Tensile tests were conducted, and the results were - [64]
Laser shock peening applied.
tensile testing evaluated with finite element analysis by using
Johnson-Cook parameters.
• Post heat-treatment resulted in homogeneous
Hitzler et al. (2016) AlSi10 Mg Tensile microstructure, thereby exhibiting remarkable SLM 280HL machine [65]
improvement in ductility.
Laser power 350 W, hatch spacing 0.42
mm, scan speeds 600–930 mm/s, base • The fracture toughness was found to be 40.63 KMPa.m0.5 .
Hitzler et al. (2017) AlSi10 Mg plate heating 200 ◦ C. Fracture toughness • The vertical-built samples were found to have poor SLM 280HL machine [66]
Build orientation: horizontal, inclined fracture toughness.
(45◦ ), and vertical.
• The elastic modulus, tensile strength, and elongation
were found to be sensitive to the part print orientation.
• For the non-heat-treated condition, the Young’s modulus
Laser power 350 W, hatch spacing 0.42 varied from 62.5 to 72.9 GPa, the Poisson’s ratio ranged
mm, scan speeds 600–930 mm/s, base from 0.29 to 0.36, UTS from 314 MPa to 399 MPa,
Hitzler et al. (2017) AlSi10 Mg Tensile, surface hardness SLM 280HL machine [67]
plate heating 200 ◦ C, nitrogen
and elongation from 3.2% to 6.5%.
atmosphere.
• The heat-treated samples exhibited dissimilar responses
to an additional aging procedure and were dependent on
the build height.
Materials 2020, 13, 4301 13 of 51
Table 1. Cont.
Evaluated
• Young’s modulus of the printed samples exceeded
the nominal value of ∼70 GPa.
Laser power 400 W, layer thickness • Vertical-built samples showed the least
Hitzler et al. (2018) AlSi10 Mg Tensile, compression elastic modulus. SLM 280HL machine [68]
50 µm, nitrogen atmosphere.
• A maximum compressive strength value of
530 MPa was attained.
• The results show that the temperature and molten
pool depth gradually increases with new layers
and energy input.
Laser energy input 700–1300 J/m, • The cooling rate increases progressively while the
CFD model, thermal
Hu et al. (2016) AlSi10 Mg layer thickness 50 µm, argon solidification morphology parameter decreases - [69]
gradient
atmosphere. with the increase of energy input.
• The increase in energy input lead to non-linear
increase in melt pool depth and remelting depth.
• The as-built samples achieved a relative density of
99.9%. After heat treatments, Si forms polygonal
Laser power 400 W, protective precipitates whose size increases as the
atmosphere. temperature increases. This results in a decrease
Heat treatment: Stress-relieving in tensile strength and hardness with heating up
(heating rate of 10 ◦ C/min until to 450 ◦ C.
Iturrioz et al. (2018) AlSi10 Mg Tensile, hardness, density SLM 280HL machine [70]
300 ◦ C for 2 h), Solution-treated at
• T6 heat treatment (550 ◦ C for 2 h followed by
450 ◦ C and 550 ◦ C for 2 h, followed
ageing at 180 ◦ C for 12 h) was found to be best
by water quenching, and T6 heat
performing, which yielded the tensile strength of
treatment.
307 ± 8 MPa, hardness 101 ± 4 HV and ductility
9 ± 3%.
• The horizontal build orientation yielded better
tensile strength when compared to samples built
in the vertical orientation. Furthermore,
microstructure revealed anisotropy and its
Laser power 250 W, beam diameter dependency on build orientation.
Jawade et al. (2020) AlSi10 Mg 0.2 mm, layer thickness 50 µm, Tensile Renishaw AM 250 [71]
• The UTS was found to be maximum on horizontal
scanning speed 500 mm/s.
orientation (401.89 MPa), yield strength
(301.26 MPa) and elongation of 4.3%, which is
superior than the counterpart at
vertical orientation.
Laser power 370 W, scan speed • The hardness and tensile strength improved by
AlSi10 Mg ranging from 900–1900 mm/s, scan approx. 10% and 20%, respectively, with the Concept Laser M2
Jiang et al. (2018) Tensile, hardness, density [72]
composite spacing 105 µm, layer thickness addition of 1 wt% CNTs. Cusing SLM system
30 µm, zigzag scan strategy.
Materials 2020, 13, 4301 14 of 51
Table 1. Cont.
Evaluated
• Microstructure of the samples printed using
optimised process parameters consisted of
Hatch spacing 190 µm, layer extremely fine Al-Si eutectic dispersed within
thickness 30 µm, volume energy primary α-Al dendrites.
density 26–54 Jmm−3 , laser power • Hardness in the transverse direction was higher
Porosity, microhardness,
310–390 W, scanning speed than that along the longitudinal direction.
Jing et al. (2019) AlSi10 Mg tensile testing and fracture EOS 83 M290 SLM [73]
1300–1900 mm/s, chamber pressure
morphology • The engineering stress-strain curve at different
0.45 mbar.
orientations also shows anisotropy in the strength
and ductility, which is possibly due to the
Vertical.
orientation between the tensile stress and crystal
growth direction.
• Ultrafine microstructure consisting of cellular
α-Al and nano-sized Si particles was found due to
the high cooling rate of the SLM process
• As the laser scanning speed increases, both tensile
Laser power 400 W, scanning speed strength and ductility of SLM processed Realizer SLM 250
Kang et al. (2017) AlSi12 5000 mm/s, layer thickness 50 µm Tensile samples decrease. [74]
machine
and hatch distance 45 µm.
• Higher energy density was required to fabricate
dense samples from in-situ SLM fabrication using
elemental Al and Si powders, compared to
pre-alloyed Al-12Si powders.
• Mechanical properties of printed parts
200 W fiber laser, laser beam comparable or even exceeding those of
diameter 150 µm, scan speed conventionally cast AlSi10 Mg. Modified Concept
Kempen et al. (2012) AlSi10 Mg 1400 mm/s, scan spacing 105 µm. Tensile Laser M1 SLM [4]
• Maximum UTS observed for vertical samples
Build orientation: Horizontal and Machine
396 ± 8 MPa, but the elongation was better for the
Vertical.
horizontal orientation 5.55 ± 0.4%.
• Samples printed in the Z-orientation has to be
Laser power 300 W, laser spot size compensated for the width of the melt pool.
Surface roughness, In-house built SLM
Kempen et al. (2014) AlSi10 Mg 80 µm, scan speed 1600 mm/s. [75]
Metrology • Samples printed in the XY-orientation showed machine
Build orientation: XY and Z.
dross formation.
200 W fiber laser, laser beam • Mechanical properties of printed parts
diameter 150 µm, scan speed comparable or even exceeding those of high Modified Concept
1400 mm/s, scan spacing 105 µm and pressure die cast AlSi10 Mg.
Kempen et al. (2015) AlSi10 Mg Tensile, Hardness Laser M1 SLM [76]
layer thickness 30 µm.
• Hardness found to be 152 ± 5 HV after ageing at Machine
Build orientation: Horizontal
175 ◦ C for 6 h.
and Vertical.
Materials 2020, 13, 4301 15 of 51
Table 1. Cont.
Evaluated
170 to 200 W fiber laser, laser beam • Narrow process window to obtain optimal density and
diameter 150 µm, scan speed surface quality for printed parts.
Modified Concept
200–1400 mm/s, scan spacing 105 µm • Higher scan speed of 1400 mm/s was used for high
Kempen et al. (2011) AlSi10 Mg Density, Roughness Laser M1 SLM [77]
and layer thickness 30 µm. density/productivity demands, whereas lower scan speeds
Machine
Build orientation: Horizontal and of 1100–1200 mm/s were used for parts with a high demand
Vertical. in top surface quality.
• Significant stress partitioning exists between the Si
Laser power 200 W, scanning speed (680 MPa) and Al (260 MPa) constituents.
Concept Laser M2
Kim et al. (2016) AlSi10 Mg 1500 mm/s, bidirectional scanning Tensile • The fracture analysis reveals large voids and cracks in the [78]
machine
vector. microstructure, particularly in the soft Al matrix
under loading.
• Relative density of 99.8% could be obtained by optimizing
the laser irradiation conditions.
Laser power 200–370 W, scan speed • Tensile strength of 400 MPa, yield strength of 200 MPa,
Kimura and 400–3000 mm/s, scan spacing
A356 Tensile, Density and elongation of 12–17% was obtained for optimally EOSINT M280 SLM [20]
Nakamoto (2016) 0.08–0.18 mm, layer thickness of
printed samples.
30 µm.
• After annealing the UTS reduced to 250 MPa and yield
strength to 125 MPa, however, elongation increased to 30%.
200 W Yb fiber laser, layer thickness • Hatch distance is the most influential process parameter
20–40 µm, beam diameter 0.1 mm, affecting the print part density.
Krishnan et al. (2014) AlSi10 Mg laser power 180–195 W, scanning Hardness, Density • There is a close correlation between the geometry of scan - [79]
speed 700–900 mm/s, hatch distance tracks and macroscopic properties of the printed parts.
0.1–0.25 mm, nitrogen atmosphere. • The optimal energy density was found to be 1.2–1.8 J/mm2 .
Laser power 350 W, beam diameter • The solubility of Si in the Al matrix of the as-built samples
80 µm, scan speed 1140 mm/s, layer was found to be about 8.89 at%, which significantly
thickness 50 µm, scan spacing decreased after solution heat treatment, and further
170 µm, argon chamber atmosphere, decreased with ageing treatment.
Li et al. (2016) AlSi10 Mg substrate plate pre-heated to 100 ◦ C. Tensile, hardness SLM250 HL [80]
• The tensile strength decreased from 434.25 ± 10.7 MPa for
Heat treatment: T6 treatment,
the as-built specimens to 168.11 ± 2.4 MPa for the specimens
solution treated at 450 ◦ C, 500 ◦ C,
that were solution heat-treated only. However, the fracture
and 550 ◦ C for 2 h, water quenched,
strain increased from 5.3 ± 0.22% to 23.7 ± 0.84%.
and aged at 180 ◦ C for 12 h.
• The tensile strength and elongation of the horizontally-built
samples are 340 MPa and 11.2%, respectively, compared to
Build orientation: Horizontal 350 MPa and 13.4%, respectively, for the
(Y-direction) and Vertical vertically-built samples.
Li et al. (2017) AlSi10 Mg Tensile - [81]
(Z-direction), tensile testing carried
• The microstructure revealed fish-scale morphology along
out at −71 ◦ C.
the Y-build direction and oval shaped structure in the
Z-build direction.
Materials 2020, 13, 4301 16 of 51
Table 1. Cont.
Evaluated
• Spherical Si particles with size less than 100 nm
Laser power 200 W, scanning speed formed at the Al grain boundaries. However, the
500 mm/s, layer thickness 50 µm, coarse and fine Si precipitates were found to be
scan spacing 150 µm, substrate Tensile, residual stresses, homogeneously distributed in the Al matrix. ReaLizer SLM-100
Li et al. (2015) AlSi12 [82]
heated to 200 ◦ C, argon atmosphere. FEM • The ultrafine eutectic microstructure yields machine
Heat treatment: Solution treated at significantly better tensile properties and an
500 ◦ C for 4 h and water quenched. extremely high ductility of approx. 25% after
solution heat treatment.
• A 3D FE model was developed to simulate the
thermal behaviour and melt pool dimensions of
the printed parts.
• The cooling rate of the melt pool reduced from
Laser power 200 W, hatch spacing 7.93 × 106 ◦ C/s to 3.61 × 106 ◦ C/s as the laser
80 µm, laser spot diameter 80 µm, exposure time is increased from 100 µs to 180 µs. Renishaw AM 400
Li et al. (2018) AlSi10 Mg layer thickness 25 µm, exposure time Modelling and simulation Alternatively, with an increase in point distance SLM system [83]
100–180 µs, point distance from 60 µm to 100 µm, the cooling rate increased (Renishaw PLC)
60–100 µm. from 3.25 × 106 ◦ C/s to 7.48 × 106 ◦ C/s.
• The melt pool size (width and depth) increased as
the laser exposure time is increased,
and vice-versa when the point distance
is increased.
• SLM experimental results validated the obtained
thermal behavior in simulation.
• The cooling rate increased from 2.13 × 106 ◦ C/s to
Laser power of 150–300 W, laser spot 2.97 × 106 ◦ C/s when the laser power was
diameter 70 µm, scanning speed increased from 150 W to 300 W, and from
Li and Gu (2014) AlSi10 Mg 100–400 mm/s, layer thickness 50 µm, Modelling and simulation 1.25 × 106 ◦ C/s to 6.17 × 106 ◦ C/s when the scan YLR-500-SM [84]
hatch spacing 50 µm, argon speed increased from 100 mm/s to 400 mm/s.
atmosphere. • A sound metallurgical bonding between the
neighboring layers was obtained at the optimized
combination of process parameters, including
laser power of 250 W and scan speed of 200 mm/s.
• An 80% decrease in surface roughness was
observed when the printed parts were
sand blasted. M2 Cusing from
Tensile, hardness, density,
Liu et al. (2010) AlSi10 Mg Laser power 200 W • The tensile properties of the as-built samples Concept Laser, [85]
roughness
tested at both room temperature and high Germany
temperature (200 ◦ C) are significantly better than
the conventionally heat-treated cast parts.
Materials 2020, 13, 4301 17 of 51
Table 1. Cont.
Evaluated
• The cooling rate for the layers printed at the top
region of the sample was determined to be about
1.44 × 106 K/s, which is significantly higher than
Laser power 500 W, scan speed that experienced by the bottom layers
1500 mm/s, layer thickness 30 µm, (≤1 × 103 K/s).
Hardness, wear resistance, BLT-S300 SLM
Liu et al. (2018) AlSi10 Mg zigzag scan strategy, scanning angle [86]
modelling and simulation • The top surface area has a lower degree of machine
alternated by 90◦ for
crystallinity of Al matrix than that of core area.
subsequent layers.
• The surfaces of the printed samples exhibited
higher hardness and wear resistance compared to
the core regions.
• The cooling rate, temperature gradient and the
solidification rate increase with an increase in
Laser power 160–200 W, spot size laser power and decrease with an increase in
Liu et al. (2018) AlSi10 Mg 100 µm, scanning speed Modelling and simulation scanning speed. IPG YLR-200 [87]
200–1000 mm/s, argon atmosphere. • Along Z direction, the cooling rates and the
temperature gradient are lower compared to
Y direction.
Laser power 50–100 W, laser spot
size 80 µm, hatch spacing • The formation of oxides can be avoided by using
0.05–0.3 mm, scan speed range high laser powers while printing. MCP Realizer 100
Louvis et al. (2011) AA 6061 Density [8]
75–1000 mm/s, layer thickness 50 µm, • The maximum relative density was obtained at SLM machine
argon atmosphere, point distance high laser power of 100 W (89.5%).
65–85 µm
For AA 6061: Laser power • The microstructure of AA 6061 parts did not show
300–370 W), scanning speed the same fibrous Si network that formed inside the
800–1300 mm/s, hatch spacing AlSi10 Mg microstructure due to lower Si content.
0.1–0.19 mm, energy density • The size of the melt pool increases with an
Maamoun et al. AlSi10 Mg & 40.5–123.3 J/mm3 . increase in energy density. An energy density
Tensile, hardness range of 50 to 60 J/mm3 was found to be optimum - [88]
(2019) AA 6061 For AlSi10 Mg: Laser power
200–370 W), scanning speed to significantly minimize the formation of keyhole
1000–1300 mm/s, hatch spacing defects and porosities.
0.15–0.25 mm, energy density • Maximum tensile strength of both the AlSi10 Mg
27–65 J/mm3 . and AA 6061 printed samples was 396.5 MPa.
• The tensile strength is not significantly affected by
the build orientation of the printed samples.
Laser power 350 W, scanning speed • Samples built perpendicular to the build direction
1650 mm/s, layer thickness 30 µm, failed at greater strain than those built parallel to
Maconachie et al. Tensile, dynamic behaviour
AlSi10 Mg hatch spacing 130 µm and beam the build direction. SLM500 [89]
(2020) in tension (SHTB), fracture
diameter 90 µm.
• The anisotropic properties of the samples were
Build Orientation: 0◦ , 45◦ and 90◦ .
insensitive to the strain rate applied during
mechanical testing.
Materials 2020, 13, 4301 18 of 51
Table 1. Cont.
Evaluated
Laser power 320 W, hatch spacing 0.08 mm,
layer thickness 30 µm, scanning speed • As the wall thickness increased from 0.5 mm to 1.5
900 mm/s, checkerboard scanning strategy, mm, an increase in porosity was observed.
argon atmosphere. • Ageing heat treatment resulted in better density of
Heat Treatment: T4 treatment involving the thin wall samples.
Majeed et al. (2019) AlSi10 Mg Density, tensile, fracture 280 HL SLM [90]
solution heat treated at 530 or 540 ◦ C for 2 h
• The size of the pores increased till the wall
and water quenched. T6 treatment
thickness of 1.5 mm and then decreased with
involving solution treated at 530 ◦ C for 2 h,
further increase in wall thickness.
water quenched and artificially aged at
155 ◦ C for 12 h.
Laser power 200 W, layer thickness 25 µm, • The elongation at break for the heat-treated
hatch spacing 130 µm, scanning speed material was nearly three times greater than that
571 mm/s, point distance 80 µm, exposure observed for the as-built material, and the fatigue
time 140 µs, build platform temperature strength at 106 cycles was around 1.6 times Renishaw AM250
Maskery et al. (2015) AlSi10 Mg Tensile, fatigue [91]
180 ◦ C, hatch rotation 67◦ . as high. SLM machine
Heat treatment: Solution treated at 520 ◦ C • The UTS was reduced from 330 ± 10 MPa to
for 1 h, water quenched, and aged at 160 ◦ C 292 ± 4 MPa and the ductility enhanced from
for 6 h. (1.4 ± 0.3)% to (3.9 ± 0.5)%.
Laser power 150 W, scanning speed • Anisotropy due to different build orientations was
1000 mm/s, hatch spacing 50 µm, and layer found even after post stress relief heat treatment.
thickness 50 µm. Tensile, fatigue crack
• Maximum relative density was reported for XY SLM Solution M280
Mfusi et al. (2019) AlSi10 Mg Build Orientation: XY, 45◦ , and Z growth, fracture toughness, [92]
printed samples (97.33 ± 0.92%). However, GmbH
orientations. density, hardness, porosity
maximum hardness was reported for the 45◦
Heat treatment: Stress relief treatment at
orientation printed samples (47.32 ± 3.35 HV).
300 ◦ C for 2 h followed by furnace cooling.
Laser powers 200 W and 400 W.
Build Orientation: XY and Z • The improvement in fatigue resistance is less
Heat treatment: Stress relieved at 160 ◦ C for pronounced when large-sized defects are present Phenix PM100 3D
Ngnekou et al. (2017) AlSi10 Mg 1 h or 300 ◦ C for 2 h, T6 heat treatment Fatigue in the printed samples. Systems machine [93]
involving solution treated at 540 ◦ C for 8 h, • There is no influence of the defect type on the EOS M290 machine
water quenched, and tempered at either fatigue limit.
20 ◦ C for 24 h or 160 ◦ C for 10 h.
Laser power 400 W, spot diameter 80 µm,
scan velocity 1000 mm/s, strip scanning • The dynamic anisotropic properties were
strategy, hatch distance 200 µm, hatch insensitive to variation in strain rates.
rotation 67◦ , layer thickness 60 µm, argon • Anisotropic differences were considerably
Nurel et al. (2018) AlSi10 Mg Dynamic-Compression EOSINT M280 system [94]
atmosphere, build plate temperature 35 ◦ C. reduced by applying T5 heat treatment.
Build orientation: Horizontal and Vertical • The as-built samples failed after SHPB tests which
Heat Treatment: T5/Stress relief treated at was observed in the T5 heat treated samples.
300 ◦ C for 2 h.
Materials 2020, 13, 4301 19 of 51
Table 1. Cont.
Evaluated
Laser power 400 W, spot diameter
80 µm, layer thickness 30 µm. • No strain sensitivity was observed.
Nurel et al. (2018) AlSi10 Mg Build orientation: Horizontal and Dynamic-Compression • True stress for as-built and heat-treated conditions EOSINT M280 system [95]
Vertical. are 569 ± 8.5 MPa and 427 ± 4.8 MPa respectively.
Heat treatment: T5 at 300 ◦ C for 2 h.
• FEA was carried out to investigate temperature
Laser power 100 W, scanning speed evolution, heat transfer and solidification process.
Ojha et al. (2018) AlSi10 Mg 2000 mm/s, spot size 0.2 mm, layer Modelling and simulation - [96]
• Simulation results are dependent on process
thickness 80 µm.
parameters along with material properties.
• The perturbation or the instability within the
molten pool results in the formation of pores
Laser power 180 W, scanning speed during SLM, which have a direct influence on the
Pei et al. (2017) AlSi10 Mg 600–1600 mm/s, layer thickness Modelling and simulation densification level. SLM-150 equipment [97]
35 µm, spot size 70 µm. • At high scanning speed, the track morphology
became discontinuous leading to poor bonding
and balling.
• Post-treatment is effective in reducing surface
roughness and inducing compressive residual
Fatigue, porosity, surface stresses on the material surface.
Pola et al. (2019) AlSi10 Mg - EOS M290 system [98]
roughness, tensile
• Sand blasting had a beneficial effect of the
fatigue resistance.
• The dynamic compressive strength increased with
Laser power 285 W, scanning speed an increase in the angle of print orientation, i.e.,
1000 mm/s, hatch spacing 100 µm, from 0◦ to 90◦ .
layer thickness 40 µm, defocus • The yield strength and compressive strength
Ponnusamy et al. decrease for printed samples tested at elevated
AlSi12 distance −4 mm, alternative scan Dynamic - Compression 3D Systems ProX 200 [99]
(2018) temperature of 200 ◦ C.
strategy.
Build orientation: Horizontal, • The flow stress was found to be higher for
Inclined, Vertical dynamic loading compared to quasi-static loading
at elevated temperature.
Laser power 285 W, scanning speed • Thermal softening was observed in printed
1000 mm/s, hatch spacing 100 µm, samples tested at elevated temperatures, which
layer thickness 40 µm, defocus resulted in significant reduction in flow stress.
distance −4 mm, alternative scan • A 20% and 50% reduction in flow stress was
Ponnusamy et al.
AlSi12 strategy, hexagon scan pattern, argon Dynamic compression observed when samples were tested at 200 ◦ C and ProX 200 [100]
(2020) 400 ◦ C test temperatures, respectively.
atmosphere.
Build orientation: Vertical • A 12% and 45% reduction in flow stress was
Heat treatment: Annealed at 200 ◦ C observed for samples heat treated at 200 ◦ C and
and 400 ◦ C for 3 hrs. 400 ◦ C, respectively, and then tested.
Materials 2020, 13, 4301 20 of 51
Table 1. Cont.
Evaluated
Laser power 320 W, layer thickness
50 µm, hatch spacing 110 µm, hatch • As-built samples exhibit better wear resistance
rotation 73◦ , scanning speed and similar corrosion resistance compared to
1455–1939 mm/s, argon atmosphere. Wear rate, corrosion cast counterparts.
Prashanth et al. (2014) AlSi12 SLM 250 HL [16]
Build orientation: 30◦ , 45◦ , 60◦ , properties • Both wear and corrosion properties deteriorated
75◦ , 90◦ . with annealing post heat treatment, due to growth
Heat treatment: Solution treated at of Si precipitates.
473–723 K for 6 h.
Laser power 320 W, layer thickness • The difference in tensile properties were attributed
50 µm, hatch spacing 110 µm, hatch to the variation in crack propagation path.
rotation 73◦ , scanning speed • The samples printed without contour exhibited
1455–1939 mm/s, argon atmosphere, significant increase in ductility without
scan strategies included single melt, compromising on the tensile strength.
Prashanth et al. (2017) AlSi12 Tensile SLM 250 HL [101]
double melt, single melt continuous, • The results indicate that the room temperature
and checkerboard, base plate heating tensile properties can be tuned (between YS:
473–673 K. 115–290 MPa, UTS: 220–460 MPa and ductility:
Heat treatment: Solution treated at 2.8–9.5%) in-situ with appropriate selection of
473–723 K for 6 h. process parameters.
• The Al and Si phases show remarkably small
Laser power 320 W, layer thickness crystallite sizes of about 118 and 8 nm.
50 µm, hatch spacing 110 µm, hatch • The as-built samples exhibited a yield strength of
rotation 73◦ , scanning speed 260 MPa and tensile strength of 380 MPa, which
1455–1939 mm/s, argon atmosphere. was significantly higher than the
Prashanth et al. (2014) AlSi12 Tensile SLM 250 HL [17]
Build orientation: 30◦ , 45◦ , 60◦ , 75◦ , cast counterparts.
90◦ . • The texture of the microstructure of the printed
Heat treatment: Solution treated at samples varied with variation in build
473–723 K for 6 h. orientations, however, this did not affect the
tensile properties.
• The dimensions of the melt pool increased with an
increase in laser power resulting in strut
diameters deviating from the designed values.
• The compressive load bearing capacity of the
Laser power 150–400 W, beam spot lattice structures increased with an increase in
Concept Laser M2
Qiu et al. (2015) AlSi10 Mg size 50 µm, scanning speed Compression strut diameter. [102]
Cusing SLM system
1000–7000 mm/s. • Deformation of lattice structures occurred by
homogeneous deformation until the maximum
stress was achieved after which the structure lost
structural integrity via a series of shear banding
events at around 45◦ to the compression axis.
Materials 2020, 13, 4301 21 of 51
Table 1. Cont.
Evaluated
• Printed samples displayed superior tensile strength
(~350 MPa) and impact strength compared to
Laser beam diameter 80 µm, cast parts.
argon/nitrogen gas inert atmosphere. EOSINT M280
Rakesh et al. (2018) AlSi10 Mg Tensile, Impact strength • Significant improvements in tensile properties and [103]
Build orientation: Transverse (XZ), machine
impact energies were observed in the
Longitudinal (Y)
transversely-built samples irrespective of the
chamber atmosphere.
Laser power 100–370 W, layer thickness • The mechanical property was largely affected by
30 µm, hatch distance 0.1 mm, spot size different substrate temperatures.
diameter 0.1 mm, scan speed
Rao et al. (2016) A357 Tensile • The coarse Si precipitates formed along the build EOSINT M280 [25]
500–5000 mm/s, substrate temperature
direction facilitates intercellular failure, resulting in
35–200 ◦ C.
poor tensile properties.
Build orientation: Horizontal, Vertical.
Laser power 100–370 W, layer thickness • The as-built samples had an ultrafine microstructure,
30 µm, hatch distance 0.1 mm, spot size with high residual stresses and non-equilibrium solid
diameter 0.1 mm, scan speed solute concentration of Si in the supersaturated
500–5000 mm/s, substrate temperature Al matrix.
35–200 ◦ C. • The tensile properties of the printed A357 samples
Rao et al. (2017) A357 Tensile were comparable or better than the traditional EOSINT M280 [24]
Heat treatment: Stress relieving at
300 ± 1 ◦ C and air-cooled, solution cast counterparts.
treating at 535 ± 3 ◦ C in salt bath from • The UTS and YS of as-built sample are 426.4 ± 2.6 MPa
0.25 h to 150 h followed by water and 279.6 ± 1, respectively, however, the ductility was
quenching. found to improve after stress-relieving (13.6 ± 0.6%).
• Energy per layer in the range of 504–895 J yielded ≥
Laser power 285 W, scan speed 99.8% relatively dense AlSi12 SLM-printed samples.
1000–2000 mm/s, layer thickness 40 µm, • Yield strength range 225–263 MPa, tensile strength
hatch distance 100 µm, defocus distance range 260–365 MPa, and ductility range 1–4% was
Rashid et al. (2018) AlSi12 Tensile, density ProX 200 [104]
–4 mm. found for the printed samples with different
Build orientation: Horizontal, Inclined build orientations.
(45◦ ), Vertical • Anisotropy in mechanical properties was attributed to
differences in relative densities.
• The printed samples exhibited brittle failure.
Laser power 285 W, scan speed • Triangular lattice structure had the highest flexural
1000–2000 mm/s, layer thickness 40 µm, strength of 175.80 ± 1 MPa, circular 151.35 ± 0.67 MPa,
hatch distance 100 µm, defocus distance and honeycomb 143.16 ± 3.85 MPa, whereas the solid
Rashid et al. (2017) AlSi12 Flexural specimen had a strength of 290 ± 26 MPa. ProX 200 [105]
–4 mm.
Lattice structures: Circular cells, • Triangular lattice structure showed good flexural
honeycomb cells, triangular cells modulus of 5 GPa compared to the honeycomb
structure (4.34 GPa) and circular structure (4.37 GPa).
Materials 2020, 13, 4301 22 of 51
Table 1. Cont.
Evaluated
• Printed samples displayed significant anisotropy
Laser power 320 W, scan speed in wear rate due to change in laser
Rathod et al. (2019) AlSi12 1455 mm/s, layer thickness 50 µm, Wear track orientation. 280HL equipment [106]
and hatch spacing 110 µm.
• Porosity significantly affected the wear rate.
Laser spot size 80 µm, laser power • Porosities of the order of 5 to 20 µm were
350 W, scan speed 1650 mm/s, layer observed in relatively dense (99.13%) sample.
thickness 30 µm, hatch distance 0.13 Tensile, hardness, impact
Raus et al. (2017) AlSi10 Mg • Printed samples displayed higher mechanical SLM 125 HL [107]
mm, stripe scanning strategy, argon toughness
properties compared to high pressure die
atmosphere, build platform
cast samples.
Laser power 100–200 W, laser track • A critical energy density of 60 J/mm3 was found
width 150 µm, layer thickness 30 µm, wherein minimum pore fraction was observed.
scan speed 700–2000 mm/s, hatch
• Creep results showed better rupture life than cast
spacing 0.2–0.8 mm, island scanning Concept Laser M2
Read et al. (2015) AlSi10 Mg Tensile, creep resistance alloy, displaying good agreement with the [108]
strategy, island size 2–8 mm, argon Cusing SLM system
Larson–Miller literature data.
atmosphere.
• Unmelted powder particles give rise to local
Build orientation: Horizontal,
cracking, as observed on the fracture surfaces.
Vertical.
Laser power 400 W, laser spot size • The mechanical properties of the printed parts
100 µm, scan velocity 1000 mm/s, displayed a strong dependency on the
Rosenthal et al. (2015) AlSi10 Mg Tensile, density microstructure and are comparable or higher than EOSINT M280 [109]
strip scanning strategy, hatch
rotation 67◦ . cast part after T6 heat treatment.
Laser power 400 W, laser spot size
100 µm, scan velocity 1000 mm/s,
hatch distance 200 µm, layer
thickness 60 µm, argon atmosphere. • Horizontally built specimens absorbed more
Rosenthal et al. (2018) AlSi10 Mg Build orientation: Horizontal (X), Impact resistance impact energy compared to vertically EOSINT M280 [110]
Vertical (Z). built specimens.
Heat Treatment: T5 stress relief
treatment at 300 ◦ C for 2 h, modified
T5 at 200 ◦ C for 2 h.
100 µm, scan velocity 1000 mm/s, • Results revealed that the heat treatments
hatch distance 200 µm, layer conducted in the range of 100 ◦ C–300 ◦ C
Rosenthal and Stern
AlSi10 Mg thickness 60 µm. Hardness displayed noticeable increase in hardness values EOSINT M280 [111]
(2016)
Heat treatment: Treated at
due to precipitation/coarsening of the Si phase.
100–250 ◦ C for 2 h, treated at 200 ◦ C
for 168 h, treated at 100 ◦ C for 336 h.
Materials 2020, 13, 4301 23 of 51
Table 1. Cont.
Evaluated
• The printed parts displayed room temperature
mechanical properties comparable or even exceeding
Laser power 400 W, scanning speed conventionally cast AlSi10 Mg samples.
1000 mm/s, strip scanning strategy
• In the vertical orientation, the samples display Young’s
Build orientation: Vertical, Tensile, hardness, fracture
Rosenthal et al. (2014) AlSi10 Mg modulus of 69.5 to 73 GPa, yield strength 167–170 MPa, - [112]
Horizontal. morphology
UTS 269–277 MPa and elongation ranging 7.8–8.7%,
whereas in the horizontal orientation Young’s Modulus
300 ◦ C for 2 h.
ranges between 69–71.3 GPa, yield strength 168–170 MPa,
UTS of 267 MPa and elongation ranging 8.6–9.5%.
Laser power 400 W, laser spot size • Printed samples were sensitive to strain rate variations
100 µm, scan velocity 1000 mm/s, with significant changes to the flow stress and strain
hatch distance 200 µm, layer hardening exponents with an increase in strain rate.
thickness 60 µm, argon atmosphere, Tensile, fracture surface
Rosenthal et al. (2017) AlSi10 Mg • The strain rate sensitivity was similar in both vertical and EOSINT M280 [113]
build plate temperature 35 ◦ C, strip analysis
horizontally printed samples, while the true strain was
scanning strategy, hatch rotation 67◦ .
significantly higher in the samples built in the
Build orientation: Vertical,
horizontal orientation.
Horizontal.
• The maximum temperature of the molten pool increased
from 731 ◦ C to 2672 ◦ C and the molten pool length
Laser power ranging 70–190 W, laser changed from 0.286 mm to 2.167 mm, when the laser
Samantaray et al. spot diameter 0.2 mm, scanning power increased from 70 W to 190 W.
AlSi10 Mg Modelling and simulation - [114]
(2018) speed 100–500 mm/s, layer thickness
• The sintering depth of the powder layer increased with
1 mm.
an increase in laser power but decreased when the scan
speed was increased.
Laser power 400 W, volume energy • The microstructure of the printed samples consisted of
density 39.6 J/mm3 , argon fine grains and precipitates that resulted in increased
atmosphere. quasi-static strength compared to that of the
Siddique et al. (2017) AlSi12 Fatigue, tensile cast counterparts. SLM 250 [115]
240 ◦ C for 2 h followed by oven • The fatigue strength of the as-built hybrid samples was
cooling. comparably better than the as-built samples.
• Similar porosity percentage was found using optical
microscopy and X-ray computed tomography techniques.
Laser power 350 W, scan speed • Hot isostatic pressing post treatment resulted in
930 mm/s, hatch distance reduction of strength, however, was comparable to that of
0.19–0.25 mm, energy density Fatigue, porosity, the die-cast parts.
Siddique et al. (2015) AlSi12 SLM 250 HL [116]
20–39.6 J/mm3 , argon atmosphere. modelling and simulation • Even smaller size pores present in the vicinity of the
Heat treatment: Stress relieving at surface of the fatigue samples, significantly contributed to
200 ◦ C followed by oven cooling. the decrease in fatigue life. This surface weakness effect
was mitigated by the hot isostatic pressing post treatment.
Materials 2020, 13, 4301 24 of 51
Table 1. Cont.
Evaluated
• ◦C
Stress relief post heat treatment at 240 caused
Laser power 350 W, scan speed an increase in porosity due to the growth of pores.
930 mm/s, hatch spacing 0.19 mm, • At low stresses, the samples printed with base
layer thickness 50 µm, energy plate heating displayed higher fatigue
density 39.6 J/mm3 , scanning performance compared to the samples printed
strategy chessboard, hatch rotation Fatigue, porosity, hardness, without base plate heating.
Siddique et al. (2017) AlSi12 SLM 250 HL [14]
79◦ , argon atmosphere, base plate crack propagation testing
• Samples printed without base plate heating
consisted of higher porosity, which facilitated
Build orientation: Vertical.
samples failing from cracking due to defects. Such
an occurrence was significantly reduced in
200 ◦ C for 2 h.
samples printed with base plate heating.
• Base plate heating induces a coarser grain
Laser power of 400 W, energy microstructure in the printed samples owing to a
density 20–39.6 J/mm3 , chessboard decrease in cooling rate.
scanning strategy, hatch rotation 79◦ , • Tensile strength of the printed samples was four
Tensile, surface roughness,
argon atmosphere, base plate times that of sand-cast parts and two times that of
Siddique et al. (2015) AlSi12 residual stress analysis, SLM 250 HL [15]
temperature 200 ◦ C. die-cast parts.
fatigue
Build orientation: Vertical. • Significant reduction in residual stresses was
Heat treatment: Stress relieving at observed in samples printed with base plate
240 ◦ C followed by oven cooling. heating, which also reduced the scatter in
fatigue data.
EOS M400: Laser power 1000 W,
laser spot diameter 90 µm, nitrogen
atmosphere.
SLM 280: Laser power 400–1000 W, • The mechanical properties of the samples printed
using different SLM machines were different, even EOS M400
laser spot diameter 80–225 µm,
Silvestri et al. (2020) AlSi10 Mg Tensile SLM 280 [117]
argon atmosphere. though the best process parameters suggested by
Renishaw AM400
Renishaw AM400: Laser power 400 the equipment manufacturers were employed.
W, laser spot diameter 70 µm, argon
atmosphere.
Build orientation: 0◦ , 60◦ , 90◦ .
0.2 mm, scanning speed 730 mm/s, • The microstructural studies revealed that the
hatch spacing 0.12 mm, layer samples were stretched due to the exclusion of Si
thickness 30 µm, stripe scanning Tensile, surface roughness, enriched cellular and dendritic network.
Subbiah et al. (2020) AlSi10 Mg SLM 280 HL [118]
strategy, inert atmosphere, base plate modelling and simulation
• Printed samples exhibited high tensile strength of
431 MPa.
Heat treatment: Solution treated at
550 ◦ C for 2 h and water quenched.
Materials 2020, 13, 4301 25 of 51
Table 1. Cont.
Evaluated
100 µm, scanning speed 1000 mm/s, • A homogeneous distribution of spheroidised Si was
hatch spacing 0.165 mm, layer observed in heat treated parts.
thickness 25 µm, chessboard • It was suspected that Si experienced the necking effect
scanning strategy, hatch rotation 67◦ . under a tensile environment due to the large temperature
Sun et al. (2019) AlSi10 Mg Heat Treatment: T2 Tensile gradient and α-Al erosion during the SLM process. Renishaw AM 250 [119]
treatment—annealed at 380 ◦ C for 45
• The tensile strength of the as-built samples was better
mins and air cooled, T6-like
than the as-cast samples, however, the strength reduced
treatment—solution treated at
with subsequent post heat treatment.
500 ◦ C for 15 mins, quenched,
and aged at 158 ◦ C for 10 mins.
Laser power 320 W, layer thickness • The fatigue crack growth threshold and unnotched
50 µm, hatch spacing 110 µm, hatch fatigue strength of SLM alloys was inferior compared to
rotation 73◦ , scanning speed cast alloys, which could be attributed to tensile residual
(1455 mm/s for volume and stresses, shrinkage porosity, and un-melted particles.
Suryawanshi et al. Tensile, fracture toughness,
AlSi12 1939 mm/s for contour), argon • The printed samples exhibited enhanced toughness due SLM 250 HL [120]
(2016) fatigue crack growth
atmosphere, single melt and to the presence of mesostructure Si.
checkerboard scanning strategy.
• Toughness was found to be sensitive to crack orientation
Heat treatment: solution treated at
with respect to the build and scan orientations.
573 K for 6 h.
• A fine dislocation substructure consisting of low angle
Laser power 380 W, layer thickness boundaries was found within the α-Al grains.
30 µm, hatch spacing 0.1 mm, hatch • {001} texture along the Z direction was observed which
rotation 67◦ , argon atmosphere. was attributed to the preferential <001> grain growth of
Build orientation: Horizontal (X/Y), the α-Al phase during rapid solidification.
Takata et al. (2017) AlSi10 Mg Tensile EOSINT M 280 [121]
Vertical (Z). • The as-built samples exhibited a high tensile strength of
Heat treatment: Annealing at 300 ◦ C approximately 480 MPa irrespective of the build
for 2 h, or solution treatment at orientation. In contrast, the ductility was
530 ◦ C for 6 h and water quenched. direction-dependent, thereby resulting in the fracture
preferentially occurring at the melt pool boundaries.
Laser power 370 W, scan speed • The Z-oriented samples flow at a lower imposed stress
1300 mm/s, layer thickness 30 µm, than the XY-oriented samples.
laser spot diameter 100 µm, hatch • The maximum yield strength was noted for the XY-built
Tang and Pistorius spacing 0.16–0.22 mm, hatch rotation Tensile, fracture samples, while maximum tensile strength was observed
AlSi10 Mg EOS M280 [122]
(2017) 67◦ . morphology, porosity for the Z-built samples.
Build orientation: XY, Z. • Variation in hatch spacing results in porosity formation in
Heat treatment: Stress relieving at the printed parts, which subsequently reduced the
573 K for 2 h. tensile performance.
Materials 2020, 13, 4301 26 of 51
Table 1. Cont.
Evaluated
• A correlation between the crack-initiating pore on
Laser power 370 W, scan speed the fracture surface and fatigue life
1300 mm/s, laser beam diameter was established.
0.1 mm, layer thickness 30 µm, hatch • The fatigue resistance was affected by the
Tang and Pistorius
AlSi10 Mg spacing 0.16–0.22 mm, and the Fatigue, porosity variation in hatch spacing and build orientation. EOS M280 [123]
(2019)
Build orientation: XY, Z.
• XY-oriented samples have better fatigue
performance, possibly due to anisotropy of pores,
573 K for 2 h.
residual stress, and of melt-pool boundaries.
Laser power 175 W, laser spot size • Columnar grains were observed along building
60 µm, scan speed 1025 mm/s, layer direction, with equiaxed grains found
thickness 30 µm, scan spacing in-cross section.
97.5 µm, chess scanning strategy, • Irregular-shaped voids were observed in both the
island size 5.6 mm, argon as-built and heat-treated conditions due to the
Tradowsky et al. atmosphere. Tensile, porosity, modelling formation of oxide layer. These pores were Concept Laser M2
AlSi10 Mg considerably reduced after hot isostatic pressing [124]
(2016) Build orientation: Horizontal, and simulation cusing system
Vertical. post treatment, however, the oxide
Heat treatment: Solution treated at layers remained.
520 ◦ C for 5 h, water quenched, • Heat treated and hot isostatic pressed samples
and aged at 160 ◦ C for 12 h followed had tensile properties exceeding that of the
by air cooling. cast counterparts.
Laser power 195 W, spot size 100 µm,
layer thickness 30 µm, scanning
speed 1200 mm/s, hatch distance • The tensile strength decreased after stress relief
0.1 mm, hatch rotation 67◦ , build heat treatment.
plate temperature 100 ◦ C. • After T6 heat treatment, the microstructure EOSINT M270 Dual
Trevisan et al. (2016) A357 Tensile, hardness [125]
Heat treatment: Stress relieving at became more isotropic, and the mechanical mode machine
300 ◦ C for 2 h, T6 treatment properties were comparable to that of the
involving solution treatment at as-built condition.
540 ◦ C for 8 h, water quench,
and ageing at 170 ◦ C for 3 h.
Laser power 400 W, beam diameter
100–150 µm, scanning speed
1000 mm/s, layer thickness 30 µm • The fatigue resistance of the as-built samples was
and 60 µm (before and after melting), highest and that of the stress relieved and hot
hatch distance 200 µm, stripe Fatigue, tensile, fracture isostatic pressed samples was the lowest.
Uzan et al. (2017) AlSi10 Mg EOSINT M-280 [126]
scanning strategy, argon atmosphere, toughness, hardness • The critical stress intensity factor can be estimated
build plate temperature 35 ◦ C. by the fracture surface morphology of the
Build orientation: Z direction. fatigue specimen.
Heat treatment: Stress relieved at
300 ◦ C for 2 h.
Materials 2020, 13, 4301 27 of 51
Table 1. Cont.
Evaluated
• Lattice structures fabricated with scanning speed
of 500 mm/s achieved 10× higher stiffness than
Laser power 150–400 W, layer thickness those printed using 4000 mm/s for the same
50 µm, scanning speed 1000–4000 mm/s, geometry of the unit-cell.
Vrana et al. (2016) AlSi10 Mg Impact testing SLM 280HL [127]
nitrogen atmosphere, build platform
• Samples printed with a laser power of 350 W and
scanning speed of 3000 mm/s achieve greater
geometrical stability and had better accuracy.
• The deviation between reconstructed and
as-designed models was less than 100 µm.
Laser power 370 W, scan speed
• The anisotropic properties of the printed parts
1300 mm/s, hatch spacing 190 µm, layer were attributed to the non-uniform distribution of
thickness 30 µm, argon atmosphere. Tensile, porosity, modelling process-induced defects within the samples,
Wang et al. (2019) AlSi10 Mg EOS M290 [128]
Build orientation: Vertical. and simulation which had a deleterious effect on the
Heat treatment: Stress relieved at 250 ◦ C tensile strength.
for 4 h.
• The presence of geometric defects significantly
influenced the tensile strength and elongation.
Laser power 400 W, laser spot size • A decrease of about 20% in hardness and tensile
76 µm, scanning speed 1000 mm/s, hatch strength whereas an increase of about 155% in
distance 175 µm, layer thickness 25 µm, elongation was reported for the
chessboard scanning strategy, island size heat-treated samples.
Wang et al. (2018) AlSi10 Mg Tensile, bending, hardness Renishaw AM 250 [129]
5 mm, argon atmosphere.
• An increase of about 123% in fracture deflection
Heat treatment: T6 solution treated at
and a decrease of about 6% in bending strength
535 ◦ C for 7–15 mins and aged at 158 ◦ C
was also found for the heat-treated samples.
for 10 h.
1000 mm/s, hatch spacing 175 µm, layer • The hardness, tensile strength and bending
thickness 25 µm, chessboard scanning strength decrease by about 50% after T2
strategy, hatch rotation 67◦ . heat treatment Renishaw AM 250
Wang et al. (2018) AlSi10 Mg Tensile, bending, hardness [130]
Build orientation: Parallel, Normal. system
• The precipitates in the molten pool boundaries
Heat Treatment: T2 stress relieving
dissolve in the matrix after heat treatment.
treatment at 380 ◦ C for 45 mins followed
by air cooling.
• Insignificant differences in density and hardness
was observed when the samples were printed in
Laser power 200 W, beam diameter either argon, nitrogen, or helium
35 µm, scanning speed 375–2000 mm/s, chamber atmospheres.
Wang et al. (2014) AlSi12 hatch spacing 0.15 mm, layer thickness Tensile, hardness Realizer SLM 100 [131]
• The samples showed superior performance;
50 µm, stripe scanning strategy, hatch
1.5 times yield strength, 20% higher tensile
rotation 90◦ , inert atmosphere.
strength, and twice elongation, compared to
conventionally produced material.
Materials 2020, 13, 4301 28 of 51
Table 1. Cont.
Evaluated
• A linear energy density of 1.5–1.875 J/cm was reported
Laser spot size 70 µm, laser power to yield continuous single-track depositions.
150–180 W, scanning speed • The level of porosity was significantly influenced by
Tensile, fracture Self-developed SLM
Wei et al. (2017) AlSi10 Mg 600–1400 mm/s, layer thickness 40 µm, the variation in hatch spacing. [132]
morphology 150 equipment
hatch spacing 50–70 µm, random
• The pores and un-melted particles cause reduction in
scanning strategy, argon atmosphere.
tensile strength and strain.
• Long cell-like structures are formed in the printed
samples owing to the high cooling rate of the process.
Laser power 175 W, scanning speed • The Al within the eutectic grows epitaxially on the
Tensile, in-situ compression pre-existing Al cell resulting in further epitaxial Concept Laser M2
Wu et al. (2016) AlSi10 Mg 1030 mm/s, hatch spacing 0.65 mm, [133]
testing growth of the Al cell formed above the eutectic. system
island size 6 mm.
• Si precipitates present across the Al-matrix inhibits
dislocation motion within the large Al grains.
• Lattices with cell sizes 3–6.5 mm were very thin for a
low volume fraction of 5%, which tended to break
during printing.
Laser beam diameter 100 µm, laser • The printed samples showed good geometric
Compression, computed agreement with the CAD model.
Yan et al. (2014) AlSi10 Mg power of 400 W, layer thickness 30 µm, EOSINT M280 [134]
tomography
argon atmosphere. • The compressive modulus and strength of the printed
samples directly proportional to the volume fraction
of the lattice cells and inversely proportional to the
unit cell sizes.
Laser power 750 W, scanning speed • Anisotropy in ductility between horizontally and
1100 mm/s, hatch rotation 90◦ , build vertically built samples decrease with solution heat
plate temperature 35 ◦ C. treatments carried out for longer periods of time.
Build orientation: Horizontal, Vertical. • Negligible coarsening of the columnar grains was
Concept Laser X-line
Yang et al. (2018) A357 Heat Treatment: Directly aged at 160 ◦ C Tensile, porosity observed for all heat treatment conditions. [26]
1000 machine
for 8 h; Stress-relieved at 300 ◦ C for 2 h; • The stress relieved sample displayed highest
Stress-relieved and solution treated at elongation to fracture, primarily owing to the
543 ◦ C for 1–8 h, quenched and aged at break-up of the Si network into fully dispersed
160 ◦ C for 8 h. Si particles.
• Fracture of the printed samples at different tensile
rates reflect a change in fracture mode from
Build orientation: XY, Z. rate-independent ductile mode to rate-dependent
Dynamic and quasi-static
Zaretsky et al. (2017) AlSi10 Mg Heat treatment: T5 stress relieving at brittle mode. EOSINT M280 system [135]
tensile
300 ◦ C for 2 h.
• At high plastic strain rate range, the yield strength of
the printed samples was strain rate sensitive.
Materials 2020, 13, 4301 29 of 51
Table 1. Cont.
Evaluated
Laser power 490 W, scanning speed • Heat treatment reduces fatigue property due to
2000 mm/s, layer thickness 40 µm, the coarsening of Si precipitates.
hatch spacing 0.1 mm, hatch rotation • For most of the fractured surfaces, the crack
90◦ , argon atmosphere. initiation sites indicated a presence of surface or Self-developed SLM
Zhang et al. (2018) AlSi10 Mg Fatigue, tensile [136]
Heat treatment: Stress relieved at system (LSNF-2)
subsurface defects.
300 ◦ C for 2 h; Solution treated at
• The as-built samples display higher fatigue
530 ◦ C for h, water quenched,
property compared to heat treated samples.
and aged at 170 ◦ C for 12 h.
• Eutectic structure up to 4 µm in size containing
tiny needle-like semi-coherent Si particles were
Laser power 400 W, scanning speed observed within the Al cells.
1300 mm/s, layer thickness 30 µm, • Embedded spherical nanoscale Si particles and
hatch spacing 0.19 mm. segregated Mg and Fe were observed along the
Zhou et al. (2018) AlSi10 Mg Heat treatment: T6 solution treated Hardness cell and grain boundaries of primary Al. EOS M280 [137]
at 520 ◦ C for 0.5–4 h, water The π-Al8 Si6 Mg3 Fe precipitates were also
quenched, and aged at 160 ◦ C for identified along the boundaries.
1–24 h. • Peak hardening was observed after ageing at
160 ◦ C for 6–10 h, and remained relatively
unchanged up to 24 h treatment time.
800 mm/s, laser spot size 80 µm,
hatch spacing 0.13 mm, layer
thickness 30 µm, volumetric energy
density 62.5 J/mm3 , argon • Stress relieving post heat treatment was effective
atmosphere, build plate temperature for eliminating residual stresses.
Zhou et al. (2019) AlSi10 Mg Tensile SLM 280 HL [138]
150 ◦ C. • The printed samples exhibited tensile strength of
Heat treatment: Stress relieved at 273.2 MPa and plasticity of 15.3%.
300 ◦ C for 2 h and water quenched;
solution treated 535 ◦ C for 1 h, water
quenched, and aged at 190 ◦ C
for 10 h.
Materials 2020, 13, 4301 30 of 51
It is evident from the information presented in Table 1 that there is a lot of interest in understanding
the SLM processability of various aluminium alloys. Olakanmi et al. [139] reported in detail the
influence of process parameters, powder properties, and laser types on the densification of aluminium
alloys. Moreover, they also reported the potential issues arising during the SLM of aluminium alloys,
such as metallurgical defects, porosity, and oxidation. The primary causes for these processing
challenges include high reflectivity, high thermal conductivity, and poor flowability of aluminium
alloy powders, which, as reported by Aversa et al. [140], can be addressed by the development of new
alloys specifically designed to improve the SLM-printability of various aluminium alloys. This idea
was corroborated by Sercombe and Li [141] who reported improved microstructures and enhanced
mechanical properties of various aluminium metal matrix composites fabricated via SLM.
The primary research focus areas of most of the published literature on SLM of aluminium
alloys can be broadly classified into four categories, viz, process parameter optimization, effects of
build orientation, in-situ and post heat treatment strategies, and modelling and numerical analysis of
print-part performance as listed in the overview of publications in Table 2. It is clear from this overview
that AlSi10 Mg alloy has received maximum attention of research papers for all four research focus areas
for mechanical properties, with a large number of researchers paying attention to the effects of build
orientation and heat treatment of this alloy. More research needs to be done on process optimization and
effects of the build orientation and heat treatment of AlSi12 alloy and other two less popular A356 and
A357 alloys processed by SLM. As reported by Rometsch et al. [142] and Zhang et al. [143], these studies
aim to improve the performance of SLM-printed aluminium components via: (a) optimizing powder
characteristics, (b) optimizing process parameters to obtain 100% dense parts, (c) minimizing the
defects such as residual stresses, distortion, and cracking, (d) optimizing post heat treatment techniques
to achieve desired mechanical properties, (e) understanding the microstructural characteristics of the
print-part, and (f) anisotropic mechanical properties as a result of varying build orientation.
3. Mechanical Properties of SLM-Printed Aluminium Alloys

Characterisation of the mechanical properties of any additively manufactured part is generally
very demanding. Although ASTM F3122-14 presents standard guidelines to evaluate most of the
mechanical properties of 3D-printed metallic materials, there is no set standard developed for this
purpose, making it difficult to benchmark and/or compare the properties of the same material printed
using different AM printers with varying geometries. Therefore, extensive research has been published
to characterize various types of mechanical properties of SLM processed Al alloys under static,
dynamic, and heat treatment conditions. Table 3 is a compilation of the various mechanical properties
investigated by researchers for four main types of SLM-printed aluminium alloys, namely AlSi10 Mg,
AlSi12 , A356, and A357.
Materials 2020, 13, 4301 31 of 51
Table 2. Overview of research focus areas into four categories.
Process Parameter
Aluminium Alloy Build Orientation Heat Treatment Numerical Studies
Optimisation
[10,12,31,33,37,40–43,49,50,59, [10,11,27,28,50,57–59,63,65,67,70,80,90–
AlSi10 Mg [38,73,76,77,79,80,88,108] 61,66,68,71,73,75,81,89,93–95, 92,94,95,110,111,118,119,121,124,126,129, [29,52,69,83,84,87,96,97,114,118,128]
110,113,117,122,126,135,144] 130,136–138,145,146]
AlSi12 [34] [99,104,120] [15–18,82,100,101,106,120] -
A356 - - [20] -
A357 - [25,26,36,48,51] [24,26,32,48,125] [64]
Table 3. List of studies evaluating various mechanical properties of SLM-printed Aluminium alloys.
Property AlSi10 Mg AlSi12 A356 A357

[50,52,53,58,66,68,70,73,76,77,79,86,92,107,111,112,
Microhardness [45,131] - [125]
126,129,130,137,145]
Nanohardness [11,12,28,49,54] - - -
[4,10–12,30,33,42–44,49,53,58,63,65,67,68,70–73,76,
Tensile 78,80,81,85,88–90,92,98,103,107,109,112,113,117– [15,17,18,55,74,101,104,115,120,131] [20] [24–26,32,36,48,51,64,125]
119,121,122,124,126,128–130,132,136,138,144,146]
Compressive [11,12,38,102,134] - - -
Fatigue [27,35,37,40,92,93,98,123,126,136,144] [14,115,116,120] - [36]
[40,43,49,53,59,66,73,89,90,92,112,118,122,126,132,
Fracture Toughness [55,120] - -
144]
Dynamic [61,62,89,95] [99,100,147] - -
Creep Resistance [108] - - -
Impact [103,107,110,127,135] - - -
Wear [47,86] [106] - -
Flexural/Bending [129,130] [105] - -
Shear - - - [51]
Materials 2020, 13, 4301 32 of 51
Table 3 shows that maximum research effort has been directed to investigate the tensile properties
of SLM processed aluminium alloys. In most of these publications, effect of build orientation and
heat treatment on microhardness, yield strength (YS) and ultimate tensile strength (UTS) has been
studied. Many of these publications have also discussed the microstructure variation in the samples
arising due to rapid heating and cooling encountered in the SLM process and relate them to the
mechanical property relationships. Table 3 also reveals that some important mechanical properties
such as quasi-static compression, dynamic (high strain rate), fatigue, impact, flexural and wear have
received very little attention of researchers. These properties are of significance in many automotive,
aerospace, and biomedical applications.
Heat treatment is one of the essential processes to achieve the desired property such as the
ductility of the part produced by SLM. Ma et al. [148] have applied the heat treatment of hyper-eutectic
alloy AlSi20 to investigate the mechanical properties as well as microstructure. In the heat treatment
process, Si particles became coarser and the morphology changed from fibrous to plate like structure.
Also, as anticipated, the changes in the microstructure during heat treatment affects the mechanical
properties. A significant decrease in strength and, on the other hand, a very high increase in ductility
were observed.
A detailed description of research carried out on each of the above-mentioned aluminium alloys
is discussed below.
3.1. SLM-Printed AlSi10 Mg

AlSi10 Mg is one of the most common aluminium alloys and finds wide applications in various
industries of 3D printing applications such as automotive and aerospace. The effect of build orientations
in horizontal (H), inclined (I), and vertical (V) directions, and the effect of post heat treatment on the
tensile mechanical properties of SLM-printed AlSi10 Mg are summarized in Table 4. In most of the
studies, the tensile samples built in horizontal direction on the build plate seem to provide higher
tensile strength than the sample build in vertical direction. In most studies, it was observed that heat
treated (HT) SLM samples display reduced tensile strength and increased ductility than the as-built
(AB) SLM samples. Very few studies have been conducted to assess the effect of build orientation
on heat treated SLM samples. Table 4 also presents results of some studies carried out on fatigue
and fracture toughness of the SLM-built parts. Very few studies have been undertaken on flexural
behaviour of the printed aluminium parts. Table 4 shows results of work carried out on the quasi-static
and dynamic compression of SLM processed aluminium samples. Again, a great deal of studies
are required to understand the quasi-static compression and high strain rate dynamic tensile and
compressive behaviour of SLM-processed aluminium parts for different orientations and heat treatment
conditions. Moreover, the mechanical performance of SLM-processed aluminium alloys operating at
elevated temperatures have also not received the attention of researchers.
Table 4. Mechanical properties of SLM-printed AlSi10 Mg.
Effect of Build Orientation:

Build Orientation a Hardness b YS (MPa) UTS (MPa) Strain (%) Reference
H, V 109.7 (max) 200 360 2 [12]
241.2 (H) 379.6 (H) 8.1 (H)
H, I, V - [33]
239.1 (I) 367.8 (I) 5.7 (I)
236.8 (V) 351.8 (V) 8.3 (V)
- - 338 (H) -
H, V [43]
- 385 (V) -
Materials 2020, 13, 4301 33 of 51
Table 4. Cont.

206.74 (0◦ ,5◦ ) 366.43 (0◦ ,5◦ ) -
241.15 (0◦ , 5◦ ) 399.10 (0◦ , 5◦ ) -
H, I, V 130.6 (max) [67]
222.83 (0◦ , 85◦ ) 360.27 (0◦ , 85◦ ) -
188.15 (45◦ , 0◦ ) 330.11 (45◦ , 0◦ ) -
179.71 (45◦ , 5◦ ) 314.32 (45◦ , 5◦ ) -
208.57 (90◦ , 45◦ ) 357.49 (90◦ , 45◦ ) -
- - 340 (H) -
H, V [81]
- 350 (V) -
170 (H) (max) 277 (H) (max) -
H, V 94 [112]
170 (V) (max) 267 (V) (max) -
- 195 (H) 338 (H) 11.1 (H)

H, V [113]
187 (V) 331 (V) 11.5 (V)
- 187 (H) 284 (H) -

H, V [122]
191 (V) 274 (V) -
- 250 (H) -
H, I, V - [68]
- 190 (I) -
- 220 (V) -
127 (H) - 391 (H) -
H, V [4]
86 (V) - 396 (V) -
Effect of Heat Treatment:
AB/HT c Hardness YS (MPa) UTS (MPa) Strain (%) Reference
AB - 300 455 0.08 [44]
AB - 224.3 349.5 - [53]
AB - - 380 - [56]
AB - 265 375 - [124]
AB - - 360 6 [132]
AB 1.52 GPa 218 312 1.80 [49]
AB - 240 360 - [78]
AB 118 (Max) 186 354 - [88]
AB 2.098 GPa 270 446 8.09 [138]
248 (H) 386 (H) 8.6 (H)
AB
228 (V) 412 (V) 7 (V)
- [42]
243 (H) 323 (H) 15.3 (H)
HT-T6
223 (V) 302 (V) 16 (V)
321 (H) 471 (H) 8.6 (H)
HT-T5
292 (V) 493 (V) 6 (V)
AB 255 377 -
140.7 [58]
SR 158 256 -
HT-T6 210 284 -
AB 123 200 400 -
[63]
HT 51 100 150 -
Materials 2020, 13, 4301 34 of 51
Table 4. Cont.

AB/HT c Hardness YS (MPa) UTS (MPa) Strain (%) Reference
AB - 307 -
127 [70]
HT - 382 (max) -
AB 136 - 396 -
[76]
HT 152 - 399 -
AB 132 - 434 -
[80]
HT 95 - 168 -
AB - - 434 -
[10]
HT - 200 -
AB - - 470 -
[92]
HT - 160 -
HT-T2 53 HB (max) 105 171 - [130]
HT-T6 100 239 333 4.50 [11]
HT 143.33 - 499 - [72]
Quasi-static and Dynamic Compressive Properties:
QS/D d UCS (MPa) YS (MPa) Strain (%) Reference
QS-C 560 350 10 [38]
D-C 590 - 0.3 [94]
D-C 700 - 0.13 [61]
Fatigue and Bending Properties:
Other tests e Fatigue Strength/No. of cycles Fracture Toughness (MPa.m0.5 ) Reference
AF, FT 3 × 107 99 (max) [27]
RB 5 × 107 - [40]
AF, FT 3 × 107 94 [91]
AF, FT 107 at 125 MPa 37.4 [126]
AF, FT 120 MPa 27 [136]
AF 100 MPa (max) - [123]
- 59.06 (0◦ , 5◦ )
- 51.60 (0◦ , 5◦ )
FT (at build
[66]
orientations) - 58.03 (0◦ , 85◦ )
- 55.79 (45◦ , 0◦ )
- 50.76 (45◦ , 5◦ )
- 40.63 (90◦ , 45◦ )
Key: a —H (Horizontal), I (Inclined at 45◦ ), V (Vertical); b —Measurements reported in HV (Vickers Hardness),
unless otherwise specified differently; c —AB (As-built), SR (Stress Relief), HT (Heat-treated); d —QS (Quasi-static
testing), D-T (Dynamic-Tension testing), D-C (Dynamic-Compression testing); e —AF (Axial Fatigue), RB (Rotating
Bending), FT (Fracture Toughness).
According to Aboulkhair et al. [149], when the process parameters and scan strategy were
optimised, it would affect the density of AlSi10 Mg parts produced by SLM directly. Therefore, the
porosity component was evaluated, and the part was found to be 99.8% dense. In a study by
Read et al. [108], the mechanical properties of the SLM built AlSi10 Mg samples were found to perform
better than as-cast alloys of the same composition. The mechanical properties tested were tensile
strength, creep, and the porosity. Similarly, Li et al. [80] reported that the solution treatment of as-built
AlSi10 Mg samples produced by SLM yielded better ductility (from 5% to 24% approximately), while the
tensile strength was significantly reduced from 434 MPa to 168 MPa approximately. Li et al. [81]
investigated the as-built SLM AlSi10 Mg samples and tested them at −70 ◦ C for mechanical properties.
Materials 2020, 13, 4301 35 of 51
The fish-scale morphology along the build direction and oval structures on the direction perpendicular
to the build direction were observed.
A study by Hitzler et al. [68] focused on the anisotropic compressive behaviour of SLM AlSi10 Mg.
They found that compressive Young’s modulus was significantly higher than the Young’s modulus of
tensile loading as well as Young’s modulus of bulk base material. The compressive Young’s modulus
found to be about 82 GPa. Furthermore, they reported that the compressive yield strength was found
to be similar to tensile yield strength, however the ultimate compressive strength was obtained to be
significantly higher than the tensile strength.
Wang et al. [150] studied the effect of energy density on densification behaviour and surface
roughness of SLM AlSi10 Mg. The densification behaviour was analysed using X-ray and CT scanning.
High relative density was obtained through the point distance of 80–105 µm with an exposure time
of 140–160 µs. Furthermore, energy density was stated to have a significant influence on the surface
morphology. On one hand, the increased energy density could lead to a balling defect and, on the
other hand, reduced energy density could cause defects, such as porosity and micro-cracks.
Everitt et al. [54] investigated the hardness through nano-indentation and found that
AlSi10 Mg samples produced by SLM have higher hardness than cast counterpart. Furthermore,
the microstructural studies revealed that grain sizes were increased at the melt pool edges, which were
associated with the homogenous distribution of Si particles throughout the sample.
A study by Leon and Aghion [151] evaluated the effect of surface roughness on SLM processed
AlSi10 Mg followed by stress-relief heat treatment. They focused on corrosion resistance and corrosion
fatigue performance. Furthermore, the results of SLM processed AlSi10 Mg samples were compared
with the cast counterparts. Polishing was found to improve the corrosion fatigue life span of SLM
samples, whereas the unpolished SLM samples caused an increase in surface roughness and other
surface defects.
Ch et al. [43] studied the SLM AlSi10 Mg alloy under two different environments namely argon and
nitrogen, while building the parts in both horizontal and vertical orientations. Their microstructural
findings include cellular structure showing α-Al matrix displaying Al and Si eutectic mixture. Tensile
strengths were found to be 385 MPa and 338 MPa for the nitrogen and argon atmosphere respectively.
Furthermore, the samples built in the horizontal orientation showed a variation of about 5% in the
nitrogen environment, whereas in the vertical orientation, 7.5% variation of strength was found. Based
on their findings, nitrogen was inferred to have preference over argon as the shielding gas.
Takata et al. [121] studied the microstructure and mechanical properties of SLM processed
AlSi10 Mg samples heat treated at temperatures 300 ◦ C and 500 ◦ C. They reported that, at elevated
temperatures, fine Si phase precipitation occurred resulting in coarse eutectic Si particles. The as-built
part was found to exhibit a tensile strength of 480 MPa. Furthermore, the tensile strength was reported
to be isotropic, whereas the tensile ductility was found to be anisotropic. Even, the anisotropic property
was found to disappear at a heat-treated temperature of 530 ◦ C.
Girelli et al. [152] investigated the effect of temperature, solution treatment, and ageing on the
microstructure, microhardness, and density of SLM AlSi10 Mg. They also investigated the AlSi10 Mg
samples produced by gravity casting under the same heat treatment conditions. The as-built SLM
samples were said to exhibit superior mechanical properties than gravity casted samples due to
the refinement of grains and nano-sized Si particles. The as-built AlSi10 Mg samples had a fine
microstructure and the heat treatment was found to decrease the ultimate tensile strength but not the
yield strength.
Liu et al. [85] investigated the as-built AlSi10 Mg samples produced by SLM and reported the issues
with respect to surface roughness and mechanical properties. Sandblasting had shown a difference of
80% in surface roughness values. Furthermore, the results of tensile tests revealed superior outcome
than the die-cast counterparts. A similar behaviour was found in terms of hardness and density.
In a study by Raus et al. [107], mechanical properties namely microhardness, tensile strength and
impact toughness were investigated. The results were then compared with conventional high pressure
Materials 2020, 13, 4301 36 of 51
die cast A360 alloy. The results revealed that microhardness and yield strength were higher for the
SLM AlSi10 Mg by 42% and 31% respectively than the die cast counterparts. They used the SLM process
parameters as laser power of 350 W, scanning speed of 1650 mm/s, and hatching distance of 0.13 mm to
attain the part density of 99.13%.
Recently, Hadadzadeh et al. [61] studied the strain rate behaviour for AlSi10 Mg alloy processed
by SLM under dynamic loading in two build orientations, one horizontal and the other being vertical.
The strain rate was said to increase rapidly in both the cases, while the strain rate at vertical orientation
was ~1400 s−1 . Both the flow stresses follow a similar trend, whereas the flow stress in the vertical
orientation were stated to progress further with increase in strain.
Nurel et al. [95] have also reported the dynamic properties of SLM processed AlSi10 Mg at strain
rates of 7 × 102 –8 × 103 s−1 using SHPB. The SLM AlSi10 Mg was found to have been affected by build
orientation and heat treatment. They also investigated the anisotropic nature of SLM parts using
ellipticity after the SHPB tests, but they have not observed any strain rate sensitivity. The focus of
this research was on the significance of the build orientation at different strain rates. No significant
correlation of build orientation with respect to strain rate was found in the range of 1000–3000 s−1 .
Asgari et al. [31] have also investigated the dynamic behaviour and texture of AlSi10 Mg with build
plate heating at 200 ◦ C. Their findings showed that, in vertically built SLM samples, shock loading
did not have an influence on texture and in horizontally built samples, transition of texture was
observed (at a strain rate of 1600 s−1 ). The dynamic mechanical behaviour was investigated using split
Hopkinson pressure bar at a strain rate ranging from 150 s−1 to 1600 s−1 .
Trevisan et al. [10] reviewed the process, microstructure and mechanical properties of SLM
AlSi10 Mg. The focus was on mechanical properties coupled with very fine microstructure, which is
primarily due to rapid melting of AlSi10 Mg powder and fast solidification. The review analysed the
effect of main process parameters, namely laser power, scan speed, layer thickness, and scan strategy.
In addition, the effect of heat treatment on tensile as well as fatigue properties associated with the SLM
AlSi10 Mg samples were discussed.
3.2. SLM-Printed AlSi12

The AlSi12 alloy is increasingly gaining focus because it is a near eutectic alloy characterised by
good casting ability and high specific strength. The low melting point of this alloy provides good
castability due to its low density and good wear properties, AlSi12 is quite attractive for applications
in automotive and aerospace industries. It can be used for cryogenic applications as it can retain its
strength at low temperatures such as at high altitudes [106]. The mechanical properties of SLM-printed
AlSi12 are summarized in Table 5. It is noted that SLM processed AlSi12 alloy has received less attention
for mechanical characterization compared to AlSi10 Mg alloy in terms of heat treatment and build
orientation effects. Most of the comments mentioned earlier concerning the need for further research
on different properties mentioned for the AlSi10 Mg alloy also apply for SLM printed AlSi12 alloy.
Table 5. Mechanical properties of SLM-printed AlSi12 .
Effect of Build Orientations:

- 270 (H) 325 (H) 4.4 (H)

H, V [120]
274 (V) 296 (V) 2.2 (V)
227 (H) 260 (H) 2.0 (H)
H, I, V - [104]
263 (I) 367 (I) 4.5 (I)
224 (V) 398 (V) 5.0 (V)
Materials 2020, 13, 4301 37 of 51
Table 5. Cont.
Effect of Build Orientations:

AB/HT c Hardness b YS (MPa) UTS (MPa) Strain (%) Reference
AB - 290 460 - [101]
AB - 263 365 - [104]
AB - 201 361 4 [116]
AB 115 224 (max) 368 (max) 4.8 [131]
AB - 240 325 -
[18]
HT 138 207 -
AB - 220 418 3.9
[15]
HT 218 372 3.4
HT - 102 425 12 [55]
Dynamic Compressive Properties:
QS/D d UTS (MPa) UCS (MPa) YS (MPa) Strain (%) Reference
D-C at RT - 550 400 0.18 [99]
D-C at 200 ◦ C - 490 270 0.18 [147]
Fatigue and Fracture Toughness:
Other tests e Fatigue Strength/No. of cycles Fracture Toughness (MPa.m0.5 ) Reference
AF 109 at 60.5 ± 4.7 MPa - [15]
FT - 19.7 [120]
Key: a —H (Horizontal), I (Inclined at 45◦ ), V (Vertical); b —Measurements reported in HV (Vickers Hardness),
unless otherwise specified differently; c —AB (As-built), HT (Heat-treated); d —QS (Quasi-static testing),
D-C (Dynamic-Compression testing); e —AF (Axial Fatigue), FT (Fracture Toughness).
Siddique [14,115] reported that in automotive and aerospace industries, there is trend to replace
cast iron with Al-Si alloys to achieve light weighting in components such as engine blocks, cylinder
heads, pistons, power trains, and intake manifolds. Many of these parts are moving and operating
under dynamic loading conditions with elevated temperatures. Therefore, extensive work needs to
be done to understand the mechanical behaviour of Al-Si alloys processed by SLM under dynamic
loading, impact, wear, and elevated temperature conditions.
Prashanth et al. [17] investigated mechanical behaviour of SLM AlSi12 and reported that the yield
strength and tensile strength were 260 MPa and 380 MPa respectively. The effect of annealing on the
microstructure and on the tensile properties revealed that mechanical properties could be fine-tuned,
and wide range of strength and ductility could be achieved. In another study, Prashanth et al. [16]
evaluated the effect of annealing on tribological and corrosion properties of SLM processed AlSi10 Mg
through sliding and fretting wear tests. The sliding wear showed less wear rate when compared to
the cast parts. The studies revealed that wear properties and corrosion behaviours have a correlation
with each other, as both are strongly associated with a change in microstructure. The change in
microstructure was due to the heat treatment, as the Si particles grow, and the density decreases with
increasing annealing temperature.
In another investigation, Prashanth et al. [153] carried out compression tests on both AlSi12 –
Titanium, Niobium, and Molybdenum (TNM) composites and AlSi12 matrix produced by SLM and
studied their behaviour. The compression tests revealed that TNM composites–AlSi12 matrix had
significantly better compressive strength when compared to the AlSi12 matrix. However, the TNM
composites had revealed less plasticity. Prashanth et al. [101] also analysed the tensile behaviour of SLM
AlSi12 , where they applied the base plate heating and four different hatch styles. The samples showed
similar crystallite sizes but different textures. In addition, the samples produced with base plate heating
Materials 2020, 13, 4301 38 of 51
had lesser residual stress. The results reported were the yield strength ranging between 235 MPa and
290 MPa, while the ultimate tensile strength varied between 385 MPa and 460 MPa. Furthermore, the
ductility varied between 2.8% to 4.5%. Since the base plate heating produced desirable results, they
carried out base plate heating at three different temperatures namely 473 K, 573 K, and 673 K, which
yielded the tensile ductility of 3.5%, ~3%, and 9.5% respectively.
Siddique et al. [116] used the computer tomography for investigating the fatigue performance of
SLM AlSi12 samples. The samples revealed better or at least comparable yield strength or ultimate
tensile strength when compared to cast parts. Surface roughness was found to affect the fatigue
strength, which was improved by post processing. Furthermore, a porosity study was essential to
employ the samples for high cycle applications. The computer tomography was applied to study
the stress concentration due to porosity. In another study Siddique et al. [15] determined the effect
of process parameters and post processing on the microstructure and mechanical properties of SLM
processed AlSi12 . They performed quasi-static tests and fatigue tests for mechanical characterisation.
Furthermore, they observed extra-ordinary eutectic microstructure using scanning electron microscope.
By changing the build rate and keeping the process in control, mechanical properties obtained were
found to be better for SLM parts than cast counterparts. Moreover, Siddique et al. [14] focused on the
design considerations and mechanical properties of SLM processed AlSi12 parts. From the application
perspective, the parts were designed to perform in the high cycle environment. Therefore, the study
was more focused on very high cycle fatigue and the corresponding crack propagation behaviour in the
cyclic environment. They further investigated the base plate heating and post processing, especially
stress relieving, which are critical for the fatigue loading of AlSi12 parts. The base plate heating was
found to influence the fatigue crack initiation mechanisms.
Wang et al. [131] studied the effect of build chamber atmosphere on the SLM AlSi12 samples.
The effect of three different atmosphere namely argon, nitrogen and helium were studied for their
influence on the mechanical properties. Hardness, density, and relative density were analysed and
found to have similar attributes for all the atmospheres. However, the mechanical properties of parts
produced in argon and nitrogen atmospheres were found to be better than the helium atmosphere.
Furthermore, the mechanical properties in SLM parts were better than those produced by conventionally
made AlSi12 counterparts.
Lykov and Baitimerov [154] investigated the SLM AlSi12 to determine the process parameters to
ensure the least porosity. The samples were found to have varied microstructures and the porosity
was reported to be about 0.5%. The AlSi12 powders were found to have poor flowability. The surface
morphology revealed that samples have an uneven surface. They recommended that to reduce the
surface roughness and porosity, it was essential to use AlSi12 powder with fine fraction of about 17 µm
and the scanning strategy include double pass laser scan strategy.
Mendřický and Keller [155] focused on the precision, geometry and dimensional accuracy of
the AlSi12 parts produced by SLM. The part orientation was planned to minimise the internal stress.
The SLM part was digitised to collect the sample data. The collected data was compared with the CAD
data to evaluate for dimensional and geometrical accuracy. The deformation of the model was caused
by the internal stress on the as-built AlSi12 parts.
Šafka et al. [156] analysed the build orientation and the placement of part in the SLM build
substrate, which could reduce the amount of support structures required and improve the flexural
strength of SLM AlSi12 parts. They observed that the least energy and therefore less heat would lead to
little deformation of the printed final part.
Chou et al. [45] proposed a new approach of using pulsed SLM over the conventional SLM for
AlSi12 and achieved greater control of the heat input. In the SLM AlSi12 , Si refinement below 200 nm
was attained. Furthermore, 95% of dense parts and the hardness of 135 HV were achieved. The part
produced by pulsed SLM method yielded better hardness than the conventional cast alloy counterpart.
The cooling rate and thermal gradient had an influence on solidification phase and the microstructure.
Materials 2020, 13, 4301 39 of 51
In a study by Vora et al. [13], a novel method had been discussed to produce aluminium parts
with the anchorless SLM. This anchorless method is opposed to the regular method that uses anchor
or support for the SLM parts. Furthermore, the anchorless SLM (ASLM) could produce SLM parts
that can remain in the stress-free state. The ASLM was found to be suitable for processing eutectic
alloys, as well as hypo eutectic and hyper eutectic alloys. In addition, they studied the in-situ alloy
formation within SLM chamber. The residual stress was also found to be less with the ASLM processed
AlSi12 alloy.
Suryawanshi [120] investigated the tensile strength and toughness of SLM AlSi12 and found that
mechanical properties were relatively better than the cast counterparts, except the ductility. The scan
strategy especially linear vs checker-board hatch style was analysed and the later was found to have
significant effect on the tensile strength. Furthermore, the meso-structure due to the laser hatch tracking
leads to improved fracture toughness. In addition, to attain higher fatigue strength, the residual
stresses, porosity, and un-melted powder particles needed to be removed. The SLM AlSi12 was found
to give more avenues for material design and fabrication with enhanced strength and toughness.
In a study by Li et al. [82], the SLM AlSi12 was reported to have controllable and ultrafine
microstructure. The excellent mechanical properties were achieved through solution heat treatment.
They introduced a novel approach for refining the eutectic alloy of AlSi12 , which yielded better tensile
properties than cast counterparts. The solution treated AlSi12 was found to produce the tensile ductility
of ~25%. Furthermore, the tailoring of the mechanical properties according to the applications was
possible by controlling the solution heat treatment time.
Louvis et al. [8] investigated the process parameters of SLM AlSi12 to achieve uniform relative
density. The process parameters investigated were laser power and the laser scanning rate.
The investigation was extended to understand the difficulty of processing AlSi12 when compared to
stainless steel and titanium alloy. The major factor that affected the relative density was the oxidation
factor. The process parameters were varied using two different SLM machines, one with 50 W laser
power and the other with 100 W laser power. Even with the optimum process parameters combination,
the machine with 100 W laser power yielded only the relative density of 89.5%. Furthermore, it was
recommended that to produce SLM AlSi12 parts with 100% relative density, it was essential to develop
methods to disrupt the oxide formation or to prevent oxidation.
Ackermann et al. [157] studied the fabrication of thin structures and their applications using
SLM AlSi12 parts. In service, the applications of SLM AlSi12 parts were found on microelectronics,
fine mechanical structures, and automotive mechanisms. The powder characteristics such as mean
particle size and powder shape, the process parameters such as laser spot size and scanning speed
were found to influence the thickness of fine structures. They arrived at 0.21 mm as the optimum
thickness for thin structures, for sufficient strength.
Rathod et al. [106] investigated the effect of scanning strategy and heat treatment on the tribological
properties of the SLM AlSi12 parts and compared with cast alloy. The process of annealing lead to Si
precipitation resulting in the reduction of hardness. The as-built AlSi12 SLM samples were reported to
have less wear rate when compared to heat treated SLM samples and cast samples.
3.3. SLM-Printed A356 and A357

There are two other types of Al-Si alloys, A356 and A357, which have been processed by SLM.
These two alloys are also Al-Si-Mg alloys. They both contain 7%Si by weight, but they have a slightly
different Mg content. The alloy A356 is AlSi7 Mg0.3 and alloy A357 is AlSi7 Mg0.7 . Very few studies
have been made on mechanical characterisation of these two alloys processed by SLM. The mechanical
properties of SLM-printed A356 and A357 are summarized in Table 6.
Materials 2020, 13, 4301 40 of 51
Table 6. Mechanical properties of SLM-printed A356 and A357.

- 257 (H) 398 (H) 4.4

H, V [48]
216 (V) 400 (V) 2.2
- 184 (H) 284 (H) -
H, I, V [51]
- 195 (I) 298 (I) -
- 192 (V) 305 (V) -
AB/HT c Hardness b YS (MPa) UTS (MPa) Strain (%) Reference
AB * - 250 400 -
[20]
HT–T5 * - 125 200 -
AB - 279 426 -
[25]
HT 205 307 -
AB - 279 426 -
[24]
SR - 165 240 -
AB - 225 375 -
[26]
SR - 125 220 -
HT–T6 138 200 400 5.5 [32]
Fatigue and Fracture Toughness:
Other tests d Fatigue Strength/No. of cycles Fracture Toughness (MPa.m0.5 ) Reference
AF 2 × 106 at 60 MPa - [36]
Key: a —H (Horizontal), I (Inclined at 45◦ ),
V (Vertical);b —Measurements reported in HV (Vickers Hardness),
unless otherwise specified differently; c —AB (As-built), HT (Heat-treated), SR (Stress Relief); d —AF (Axial Fatigue),
FT (Fracture Toughness); *—A356 alloy.
Kimura and Nakamoto [20] optimised process parameters to arrive at dense SLM A356 (AlSi7 Mg0.3 ).
The relative density attained was 99.8% with the laser irradiation conditions. The mechanical test
results found the ultimate tensile strength of ~400 MPa, the yield strength of ~200 MPa and the
elongation from 12–17%. The heat treatment revealed the difference in microstructure and mechanical
properties of SLM A356 samples and as-cast samples. After annealing, the SLM samples became
elongated to 30%, while the tensile strength of A356 samples reduced by half the value and became
~200 MPa.
Rao et al. [25] investigated the mechanical properties and microstructure of SLM A357. The processing
parameters were optimised to achieve dense A357 samples, along with fine microstructure. The porosity
was also analysed based on relative density and laser parameters. The anisotropy of SLM A357 Al
alloy samples were investigated in the horizontal and vertically built tensile samples. Fractographic
studies revealed that horizontal orientation was better for printing the A357 tensile samples. In another
study Rao et al. [24], the tensile behaviour of SLM A357 in the as-built and heat treated condition was
investigated. The as-built sample displayed ultrafine microstructure. The tensile samples of SLM A357
were found to have better properties than their cast counterparts. The Al grains in the as-built parts
had eutectic nano-sized Si particles, contributing for higher strength. However, the nano-sized Si
particles did not favour the ductility. After the heat treatment of SLM A357, as anticipated, the tensile
ductility improved and was reported to be about 23% with reduced tensile strength.
Yang et al. [26] investigated the effect of heat treatment on SLM A357 by focusing on stress relief to
analyse the mechanical property and microstructure. For the as-built A357 samples, the rapid melting
and rapid cooling affects the intermetallic phases such as Mg2 Si precipitates. During the heat treatment
process, the breaking up of the Si network was said to occur, which lead to high ductility. Si particles at
Materials 2020, 13, 4301 41 of 51
grain boundaries were observed to coarsen. Furthermore, anisotropy was observed to disappear in
terms of affecting yield strength and ductility when the microstructure became more homogenised.
3.4. Other Aluminium Alloys Processed Using SLM

From the research perspective and for the applications with desired mechanical properties,
new Aluminium alloy are being developed and processed using SLM. These new aluminium alloys
have been developed by alloying them with new elements, such as Cu, Ni, Sc, Zr, V, and Zn, to impart
improved properties and better processing by SLM.
Aversa et al. [158] developed Al-Si-Ni alloy samples for SLM with a combination of AlSi10 Mg
and Ni powders. This combination was found to be near eutectic by composition. Furthermore,
this combination of AlSi10 Mg and Ni were reported to have better hardness than AlSi10 Mg.
The increase in hardness was mainly attributed to the addition of Ni, which was demonstrated through
nano-indentation measurements. The SLM process parameters were optimised to reduce porosity.
The results obtained with the combination of AlSi10 Mg and Ni had also yielded Al3Ni agglomerates.
Spierings et al. [159] developed Sc and Zr-modified AlMg alloys for SLM processing. The Sc
and Zr-modified Al alloy is commercially known as “Scalmalloy” and offers more advantages over
traditional 4xxx as-cast alloys. These advantages include high strength and high ductility at low
anisotropy. Furthermore, fine grain microstructure and weak texture along the build direction causes
low anisotropy. They also analysed the influence of larger scan speeds on the mechanical properties of
Scalmalloy and found that grain sizes were reduced from 1.1 µm to 600 nm.
Zhang et al. [160] investigated the manufacturing of Al-Cu-Mg alloys using SLM. They studied
the effect of process parameters on the density of SLM Al-Cu-Mg alloys. The energy density was found
to have significant influence on the densification of Al-Cu-Mg alloys. The threshold value of energy
density was 340 J/mm3 , that yielded the sample density of 99.8%. Furthermore, fine microstructure
was obtained without any imperfections and micro-cracks. A high value of ultimate tensile strength of
~400 MPa and the yield strength of ~275 MPa were obtained for the SLM Al alloy part. In addition,
they found fine grains and solid solution strengthening mechanism for the higher mechanical strength.
In another study, Zhang et al. [161] investigated the microstructure and mechanical behaviour of SLM
Al-Cu-Mg alloy and Zirconium modified SLM Al-Cu-Mg alloys. The addition of Zr had the effect
of reducing the hot cracking in the SLM part. The comparison of Zr modified Al-Cu-Mg alloy and
Al-Cu-Mg alloy was found to show an ultrafine grain with Zr addition. Furthermore, Zr modified Al
alloy had significantly higher yield strength close to its ultimate tensile strength of ~450 MPa.
Nie et al. [162] studied the effect of Zr on the formability, mechanical properties and microstructure
of SLM Al-Cu-Mg-Mn alloys. The addition of Zr to SLM Al-Cu-Mg-Mn alloy was observed to
be effective in crack controlling mechanism, grain refinement and in the controlling of mechanical
properties. The addition of Zr was found to cause the transformation of grain type from columnar
to equiaxed type. Furthermore, they investigated crack inhibition and enhancement of mechanical
properties due to the addition of Zr with SLM Al alloy.
Karg et al. [163] investigated the laser beam melting of EN AW-2219 and observed that laser
processing of EN AW-2219 (Al-Cu alloys) was very challenging. Porosity and tensile tests were
conducted for the SLM Al-Cu alloy. Then, T6 heat treatment was applied to some built samples and
the elongation was observed. The elongation was found to exceed in the build direction by a factor of
two when compared to traditional cast counterpart.
Martin et al. [164] stated that several types of aluminium alloys cannot be processed using SLM
due to the complex melting and solidification dynamics. The issues were found to be microstructures
with larger columnar grains and periodic cracks. However, they suggested methods to resolve these
issues by introducing nanoparticles that would control the solidification. Then the powder particles
were found to be qualified for SLM. Furthermore, the technique of solidification control could be
applied for the conventional process as well, where hot cracking and hot tearing occurs commonly.
Materials 2020, 13, 4301 42 of 51
Montero-Sistiaga et al. [9] studied the SLM Al7075 (Al-Zn-Cu-Mg), a wrought alloy, to improve its
density. The SLM Al7075 initially displayed poor density and micro-cracking, but it was improved by
adding 4% Si. Heat treatment was carried out to improve the hardness of SLM Al7075. Furthermore,
the focus was more on producing high strength aluminium alloys.
Aversa et al. [165] investigated the mechanical, metallurgical and the thermal properties for SLM
of Al-Si-Zn-Mg-Cu alloy. The introduction of Si was analysed with respect to Al-Zn-Mg-Cu alloy
and the crack density was found to be reduced. This crack density reduction was due to improved
molten phase fluidity and the reduction of the co-efficient of thermal expansion. Furthermore, the SLM
Al-Si-Zn-Mg-Cu alloy was found to be promising in terms of microstructure, microhardness, and the
tensile properties.
Zheng et al. [166] reported the variation of microstructure and hardness of an SLM
Al-8.5Fe-1.3V-1.7Si. Among the melt pool, three different zones namely laser melted zone, melting pool
border and heat affected zone were identified. Microhardness results of the SLM process exceeded the
as-cast counterpart. Furthermore, with the decrease in laser scanning speed, laser melted zone was
found to reduce significantly.
Croteau et al. [167] investigated the microstructure and mechanical properties of SLM Al-Mg-Zr
alloys. The energy densities applied for the fabrication of SLM parts ranged between 123 and 247
J/mm3 and the resultant relative density was verified using X-ray tomography. The alloying elements
have a significant role, where Mg acted as a solid solution strengthener and Zr contributed towards
metastable precipitates resulting in grain refinement and prevention of hot tearing. Furthermore, Zr
alloy had improved the mechanical properties.
In a study by Maamoun et al. [88], the influence of process parameters of SLM AA 6061 and
AlSi10 Mg were investigated, based on the relation between microstructure and mechanical properties.
AA 6061 is also an Al-Si-Mg alloy with a higher coefficient of thermal expansion (CTE). The process
optimisation was carried out on both the aluminium alloys to reduce the defect in microstructure.
The mechanical behaviour of the aluminium alloys was analysed through the design of experiments
and the results were presented for hardness, yield strength and ultimate tensile strength. The results
obtained was useful in improving the part quality that had reduced the post processing requirements.
Uddin et al. [168] analysed AA 6061 using high temperature heating in an SLM environment to
yield crack-free parts. The hardness was found to be 54 HV, the yield strength as 60 MPa, ultimate
tensile strength of 130 MPa and the elongation of 15%. Furthermore, they revealed that AA 6061 could
be successfully manufactured with SLM without displaying the cracking phenomenon.
4. Summary and Research Gaps

Although aluminium can be with Zn, Cu, Mg, Mn, and Si to produce age-hardening alloys, casting
alloys, and work-hardening alloys, the area of focus in this review was the Al-Si alloys processed by
selective laser melting (SLM) metal additive manufacturing technique and their mechanical properties.
The Al-Si alloy has the cast-ability and weldability, which forms the unique combination and a
suitable candidate for processing in SLM. As mentioned, the most common SLM aluminium alloys
are AlSi10 Mg and AlSi12 based on the literature review. This review has focused on classification of
published research on SLM-processed aluminium alloys in terms of research carried out on the effects
of process optimisation, build orientation and heat treatment on four main types of Al-Si aluminium
alloys. The published papers have also been categorised for various types of mechanical properties
considered in SLM parts to identify research gaps on which mechanical properties needs more in-depth
investigation from the point of view of industrial applications.
This review has revealed that even though many studies are reported for the tensile mechanical
properties of SLM aluminium alloys, very few studies were carried out on the dynamic behaviour in
tension and compression, fatigue, impact, wear, and flexural response of the printed parts. Specially
very few studies were published on high strain rate loading behaviour of parts made by any metal
based additive manufacturing processes like DMD, EBM, and SLM.
Materials 2020, 13, 4301 43 of 51
One of the other research gaps found in this review is the effect of build orientations on
the quasi-static and dynamic compression properties of SLM-processed various other aluminium
alloys. It was also observed that some important mechanical properties such as fatigue, impact,
flexural, bending, and wear have received very little attention. Moreover, the mechanical
performance of SLM-processed aluminium alloys operating at elevated temperatures has also not
received much attention. These properties are of significance in many automotive, aerospace,
and biomedical applications.
Another important research avenue is to understand the effect of machine-specific characteristics
on the properties of the printed components. It was found in this review that researchers have used
different SLM machines supplied by various machine manufacturers globally. It is interesting that the
same material when printed using different machines yield different mechanical and microstructural
characteristics. This can be attributed to the differences in the laser systems used, inherent characteristics
of the machine itself, and various other parameters which are not quite understood. Moreover,
the repeatability of the mechanical performance of printed parts using same and/or different machines
is to be further explored.
Lastly, the post heat treatment plays a crucial role in tuning the microstructural characteristics of the
printed parts and render them suitable for desired applications. Most researchers have investigated the
heat treatment protocol typically used for conventionally fabricated aluminium alloys, which may not
be ideal for SLM-printed parts, as they have different inherent properties. Therefore, further research is
required to be carried out to assess the effects of different heat treatment strategies on the performance
of printed parts.
Author Contributions: Conceptualization, S.H.M. and R.A.R.R.; formal analysis, P.P.; data curation, P.P. and
R.A.R.R.; writing—original draft preparation, P.P. and R.A.R.R.; writing—review and editing, R.A.R.R., S.H.M.,
D.R., and S.P.; supervision, S.H.M., D.R., and S.P.; project administration, S.P.; funding acquisition, S.P. All authors
have read and agreed to the published version of the manuscript.
Funding: This research was funded by Defence Materials Technology Centre (DMTC) Limited, Project 5.01.
Acknowledgments: This research project was supported by DMTC Limited (Australia). The paper has been
written in line with the intellectual property rights granted to research partners from the original DMTC project.
Conflicts of Interest: The authors declare no conflict of interest.
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Materials 2020, 13, 4301; doi:10.3390/ma13194301 www.mdpi.com/journal/materials

Table 1. List of published literature on SLM of aluminium alloys.

• Increasing the strain rate from 150 s−1 to 1600 s−1

• Chemical composition mapping and

3. Mechanical Properties of SLM-Printed Aluminium Alloys

Table 2. Overview of research focus areas into four categories.

Property AlSi10 Mg AlSi12 A356 A357

3.1. SLM-Printed AlSi10 Mg

Table 4. Mechanical properties of SLM-printed AlSi10 Mg.

Effect of Build Orientation:

Effect of Build Orientation:

- 195 (H) 338 (H) 11.1 (H)

- 187 (H) 284 (H) -

Effect of Heat Treatment:

3.2. SLM-Printed AlSi12

Table 5. Mechanical properties of SLM-printed AlSi12 .

Effect of Build Orientations:

- 270 (H) 325 (H) 4.4 (H)

Effect of Build Orientations:

3.3. SLM-Printed A356 and A357

Table 6. Mechanical properties of SLM-printed A356 and A357.

Effect of Build Orientation:

- 257 (H) 398 (H) 4.4

3.4. Other Aluminium Alloys Processed Using SLM

4. Summary and Research Gaps

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