Mesoscale Numerical Simulation and Experimental Verification of Selective Laser Melting Process of AlSi10Mg Alloy

YAN Zhiqiang; LIU Yuankang; LYU Jingxiang

doi:10.3969/j.issn.1674-6457.2026.03.015

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (3) : 134-145. DOI: 10.3969/j.issn.1674-6457.2026.03.015

Additive Manufacturing

Mesoscale Numerical Simulation and Experimental Verification of Selective Laser Melting Process of AlSi10Mg Alloy

YAN Zhiqiang^*, LIU Yuankang, LYU Jingxiang

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Abstract

The work aims to investigate the thermal properties, surface attributes, and defect characteristics of single-track and multi-track simulation models at the mesoscopic level, with a focus on the overarching macroscopic process configuration, and establish a ternary mapping model of “process configuration-physical characteristics-defect evolution” to provide theoretical support for the effective regulation and control of trajectory defects. Initially, a high-fidelity numerical model at the mesoscopic scale was developed and refined through the integration of preliminary experimental data and the finite volume method. Subsequently, simulation and experimental protocols were formulated with laser power, scanning speed, and scanning spacing as variable parameters. Then, the study investigated the evolution laws governing the characteristics of the molten pool, the progression of temperature, surface morphology, and the development of associated defects during the fabrication process of both single and multiple components. The findings indicated that the molten pool demonstrated a progression characterized by circular, elliptical, and comet-like shapes throughout the formation process. Furthermore, the preheating influence of the preceding printed layer on the adjacent powder bed during multi-pass formation could substantially extend the lifespan of the molten pool in subsequent printing stages, increasing it from 132.3 µs to 174.3 µs, which in turn enhanced the stability of the forming process. Variations in laser power (P), scanning speed (v), and scanning spacing (m) resulted in notable differences in the formation trajectories. Nevertheless, within the specified range of line energy density from 150 to 350 J/m, a positive correlation was observed between the width of the molten pool and the line energy density. With the parameter settings of P=320 W, v=1.05 m/s, and m=70 µm, the upper surface of the trajectory exhibited an optimal morphology. The numerical simulation model demonstrates a significant degree of alignment with the experimental findings, as evidenced by the observation and analysis of the surface morphology of both the melt track and the melt pool. Variations in process parameter configurations have a direct impact on the distribution of heat input, which in turn affect the dynamic behavior of the molten pool. Consequently, a judicious optimization of these process parameters can significantly enhance the accuracy of the forming process, improve surface quality, minimize defects, and ensure the performance and reliability of the final product.

Key words

selective laser melting / surface morphology / temperature evolution / process parameter / melt pool characteristics

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YAN Zhiqiang, LIU Yuankang, LYU Jingxiang. Mesoscale Numerical Simulation and Experimental Verification of Selective Laser Melting Process of AlSi10Mg Alloy[J]. Journal of Netshape Forming Engineering. 2026, 18(3): 134-145 https://doi.org/10.3969/j.issn.1674-6457.2026.03.015

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