Effect of Microstructure on Mechanical Properties of SLM-Printed Al2139 Alloy
About The Project
This work involved characterising the response of Al2139 aluminium alloy produced via selective laser melting to a range of process conditions. Microstructure development was observed and its driving mechanisms were modelled as a function of manufacturing parameters. Phase distribution and defect types were determined using optical microscopy and SEM. Mechanical performance testing, including hardness, density, and corrosion, was also conducted to understand the impact of these manufacturing parameters on material behaviour. Statistical analysis was performed to enable modelling of process variable effects on material response. This work enables informed utilisation of aluminium alloys in additive manufacturing.
Key Contribution
Correlations established between SLM parameters and material behaviour.
Microstructural features linked to density and hardness changes.
Characterization of defects and phase distribution using optical and SEM analysis.
Mechanical properties quantified through hardness, density, and corrosion tests.
Statistical analysis applied to assess parameter sensitivity and trends.
Insights offered for process optimization in aluminium alloy additive manufacturing.
Why this Research Matters
Performance of additive manufactured parts is affected by microstructure, as well as the component geometry. Investigating the effect of SLM processing parameters on materials properties reduces unknowns in mechanical strength, durability, and reliability of parts. Findings in this thesis can help close the gap towards more widespread adoption of additive manufacturing in engineering grade structural applications. The results are of significance towards more widespread use of aluminium alloys in the automotive, aerospace, and other high performance sectors.
