Comparison of AlSi7Mg0.6 alloy obtained by selective laser melting and investment casting processes: Microstructure and mechanical properties in as-built/as-cast and heat-treated conditions

Abstract AlSi7Mg0.6 alloy is widely used in the automotive and aeronautical industries, and metal additive manufacturing (AM) is a breakthrough technology that motivates foundry companies to explore its potential in these industries; however, there is no deep knowledge of the mechanical properties and their relationship to microstructure in parts obtained by selective laser melting (SLM), as there is for parts obtained by casting. In this work, a comparison of the microstructure and mechanical properties of AlSi7Mg0.6 alloy obtained by SLM and investment casting processes was made. The mechanical properties of tensile specimens processed by both technologies were evaluated by uniaxial tensile tests and microhardness measurements in as-built/as-cast and heat-treated conditions with different build orientations in the case of SLM. An advanced characterization of the microstructure by field emission scanning electron microscopy (FESEM) and x-ray diffraction (XRD) analysis was also performed. After analyzing the microstructure and mechanical properties obtained with different heat treatments, the strengthening mechanisms of the two processes were identified. It is possible to obtain improved mechanical properties with SLM processing, exceeding the typical values required for aeronautical parts obtained in investment casting heat-treated (T6), and the ductility is satisfactory. Direct aging after SLM processing can effectively strengthen the AlSi7Mg0.6 alloy and is the more effective way to improve the as-built mechanical properties.