Advanced computational techniques for predicting 3D printing distortion in selective laser melting processes of Aluminium AlSi10Mg
Article Sidebar
Published
Jun 27, 2025
Main Article Content
Abstract
Distortion for 3D printing using Selective Laser Melting (SLM) on AlSi10Mg aluminium is an important issue that affects the final manufactured product. This research aims to develop a finite element method (FEM)-based computational simulation and experimental validation to predict distortion in 3D printed products using SLM. The study results found that the variation of 3D printing position affects the resulting product's distortion and mechanical properties. The 90° part print position results in smaller distortion of 0.303 and 0.335 mm than the 0° part print position of 0.329 and 0.378, respectively, making it more suitable for high-precision applications. This study confirms the importance of scan orientation in controlling distortion in the SLM process, which can be used as a guide for optimal printing parameters. With proper orientation selection, the risk of distortion or defects in SLM products can be minimised, and industrial production efficiency can be improved.
Downloads
Download data is not yet available.
Article Details
Issue
Section
Articles
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
References
[1] J. S, R. M, S. P. AVS, N. B K, and C. U, “Study of residual stresses and distortions from the Ti6Al4V based thin-walled geometries built using LPBF process,” Defence Technology, vol. 28, pp. 33–41, 2023, doi: 10.1016/j.dt.2023.01.002.
[2] A. Y. Alqutaibi, M. A. Alghauli, M. H. A. Aljohani, and M. S. Zafar, “Advanced additive manufacturing in implant dentistry: 3D printing technologies, printable materials, current applications and future requirements,” Bioprinting, vol. 42, no. August, p. e00356, 2024, doi: 10.1016/j.bprint.2024.e00356.
[3] S. Ghosh, J. Zollinger, M. Zaloznik, D. Banerjee, C. K. Newman, and R. Arroyave, “Modeling of hierarchical solidification microstructures in metal additive manufacturing: Challenges and opportunities,” Additive Manufacturing, vol. 78, no. June, p. 103845, 2023, doi: 10.1016/j.addma.2023.103845.
[4] Y. Li, K. Zhou, P. Tan, S. B. Tor, C. K. Chua, and K. F. Leong, “Modeling temperature and residual stress fields in selective laser melting,” International Journal of Mechanical Sciences, vol. 136, no. December 2017, pp. 24–35, 2018, doi: 10.1016/j.ijmecsci.2017.12.001.
[5] R. Konečná, G. Nicoletto, L. Kunz, and A. Bača, “Microstructure and directional fatigue behavior of Inconel 718 produced by selective laser melting,” Procedia Structural Integrity, vol. 2, pp. 2381–2388, 2016, doi: 10.1016/j.prostr.2016.06.298.
[6] K. Ökten and A. Biyikoğlu, “Development of thermal model for the determination of SLM process parameters,” Optics & Laser Technology, vol. 137, p. 106825, May 2021, doi: 10.1016/j.optlastec.2020.106825.
[7] K. Prem Ananth and N. D. Jayram, “A comprehensive review of 3D printing techniques for biomaterial-based scaffold fabrication in bone tissue engineering,” Annals of 3D Printed Medicine, vol. 13, p. 100141, 2024, doi: 10.1016/j.stlm.2023.100141.
[8] A. Shrivastava, S. Anand Kumar, and S. Rao, “A numerical modelling approach for prediction of distortion in LPBF processed Inconel 718,” Materials Today: Proceedings, vol. 44, pp. 4233–4238, 2020, doi: 10.1016/j.matpr.2020.10.538.
[9] C. Yu et al., “Selective laser melting of GH3536 superalloy: Microstructure, mechanical properties, and hydrocyclone manufacturing,” Advanced Powder Materials, vol. 3, no. 1, p. 100134, 2024, doi: 10.1016/j.apmate.2023.100134.
[10] D. Xie et al., “A Review on Distortion and Residual Stress in Additive Manufacturing,” Chinese Journal of Mechanical Engineering: Additive Manufacturing Frontiers, vol. 1, no. 3, p. 100039, 2022, doi: 10.1016/j.cjmeam.2022.100039.
[11] Y. Huang, L. J. Yang, X. Z. Du, and Y. P. Yang, “Finite element analysis of thermal behavior of metal powder during selective laser melting,” International Journal of Thermal Sciences, vol. 104, pp. 146–157, 2016, doi: 10.1016/j.ijthermalsci.2016.01.007.
[12] D. Sarkar, A. Kapil, and A. Sharma, “Advances in computational modeling for laser powder bed fusion additive manufacturing: A comprehensive review of finite element techniques and strategies,” Additive Manufacturing, vol. 85, no. October 2023, p. 104157, 2024, doi: 10.1016/j.addma.2024.104157.
[13] L. Zhuo et al., “Microstructural evolution and performance optimization of SLM-fabricated W/AlSi10Mg composites,” Journal of Alloys and Compounds, vol. 1010, no. October 2024, p. 178317, 2025, doi: 10.1016/j.jallcom.2024.178317.
[14] C. Li et al., “Effect of strontium salt modification on the microstructure and creep properties of SLM-formed SiC/AlSi10Mg composites,” Journal of Materials Research and Technology, vol. 35, no. December 2024, pp. 5455–5463, 2025, doi: 10.1016/j.jmrt.2025.02.194.
[15] C. Zhang, B. Chen, H. M. Li, X. Liu, G. Zhou, and G. Gou, “Propagation characteristics of ultrasonic in SLM manufactured AlSi10Mg,” Ultrasonics, vol. 135, no. June, p. 107134, 2023, doi: 10.1016/j.ultras.2023.107134.
[16] K. Chen, Q. Lu, X. Yong, P. Zhang, H. Yan, and H. Shi, “Process parameter optimization of SLM AlSi10Mg based on Box-Behnken design and experimental study on microstructure and mechanical properties,” Materials Today Communications, vol. 46, no. April, p. 112740, 2025, doi: 10.1016/j.mtcomm.2025.112740.
[17] J. Praneeth, S. Venkatesh, and L. S. Krishn, “Process parameters influence on mechanical properties of AlSi10Mg by SLM,” Materials Today: Proceedings, no. xxxx, 2023, doi: 10.1016/j.matpr.2022.12.222.
[18] M. Pagac et al., “Prediction of model distortion by fem in 3d printing via the selective laser melting of stainless steel aisi 316l,” Applied Sciences (Switzerland), vol. 11, no. 4, pp. 1–16, 2021, doi: 10.3390/app11041656.
[19] F. Günther et al., “Characterization of additively manufactured lumbar interbody fusion cages based on triply periodic minimal surfaces,” Materials Today Communications, vol. 39, no. March, p. 108634, 2024, doi: 10.1016/j.mtcomm.2024.108634.
[20] P. Scheel et al., “Advancing efficiency and reliability in thermal analysis of laser powder-bed fusion,” International Journal of Mechanical Sciences, vol. 260, no. June, p. 108583, 2023, doi: 10.1016/j.ijmecsci.2023.108583.
[21] A. Olleak and Z. Xi, “Efficient LPBF process simulation using finite element modeling with adaptive remeshing for distortions and residual stresses prediction,” Manufacturing Letters, vol. 24, pp. 140–144, 2020, doi: 10.1016/j.mfglet.2020.05.002.
[22] T. Wu, C. Li, F. Sun, P. F. Liu, and H. B. Xia, “Reduction in residual stress and distortion of thin-walled inconel 718 specimens fabricated by selective laser melting: Experiment and numerical simulation,” International Journal of Pressure Vessels and Piping, vol. 212, no. August, 2024, doi: 10.1016/j.ijpvp.2024.105292.
[23] N. Ahmed, I. Barsoum, and R. K. Abu Al-Rub, “Numerical investigation of residual stresses in thin-walled additively manufactured structures from selective laser melting,” Heliyon, vol. 9, no. 9, p. e19385, 2023, doi: 10.1016/j.heliyon.2023.e19385.
[24] R. Zhou, H. Liu, and H. Wang, “Modeling and simulation of metal selective laser melting process: a critical review,” International Journal of Advanced Manufacturing Technology, vol. 121, no. 9–10, pp. 5693–5706, Aug. 2022, doi: 10.1007/S00170-022-09721-Z/METRICS.
[25] M. R. Condruz, T. A. Badea, and A. Paraschiv, “Numerical and experimental investigation on flexural properties of selective laser melting (SLM) manufactured strut lattices structures from Ti-6Al-4V and Inconel 625,” Materials Today Communications, vol. 40, no. August, p. 110150, 2024, doi: 10.1016/j.mtcomm.2024.110150.
[26] A. Yin, W. Yu, W. Zhu, W. Li, V. Ji, and C. Jiang, “Microstructural characterization and wear performance of shot-peened TA15 titanium alloy fabricated by SLM,” Materials Characterization, vol. 209, no. September 2023, p. 113747, 2024, doi: 10.1016/j.matchar.2024.113747.
[27] Z. Jiang, P. Xu, Y. Liang, and Y. Liang, “Deformation effect of melt pool boundaries on the mechanical property anisotropy in the SLM AlSi10Mg,” Materials Today Communications, vol. 36, no. July, p. 106879, 2023, doi: 10.1016/j.mtcomm.2023.106879.
[28] B. Chen et al., “Comparative study on microstructure, mechanical and high temperature oxidation resistant behaviors of SLM IN718 superalloy before and after heat treatment,” Journal of Materials Research and Technology, vol. 31, no. June, pp. 1535–1546, 2024, doi: 10.1016/j.jmrt.2024.06.163.
[2] A. Y. Alqutaibi, M. A. Alghauli, M. H. A. Aljohani, and M. S. Zafar, “Advanced additive manufacturing in implant dentistry: 3D printing technologies, printable materials, current applications and future requirements,” Bioprinting, vol. 42, no. August, p. e00356, 2024, doi: 10.1016/j.bprint.2024.e00356.
[3] S. Ghosh, J. Zollinger, M. Zaloznik, D. Banerjee, C. K. Newman, and R. Arroyave, “Modeling of hierarchical solidification microstructures in metal additive manufacturing: Challenges and opportunities,” Additive Manufacturing, vol. 78, no. June, p. 103845, 2023, doi: 10.1016/j.addma.2023.103845.
[4] Y. Li, K. Zhou, P. Tan, S. B. Tor, C. K. Chua, and K. F. Leong, “Modeling temperature and residual stress fields in selective laser melting,” International Journal of Mechanical Sciences, vol. 136, no. December 2017, pp. 24–35, 2018, doi: 10.1016/j.ijmecsci.2017.12.001.
[5] R. Konečná, G. Nicoletto, L. Kunz, and A. Bača, “Microstructure and directional fatigue behavior of Inconel 718 produced by selective laser melting,” Procedia Structural Integrity, vol. 2, pp. 2381–2388, 2016, doi: 10.1016/j.prostr.2016.06.298.
[6] K. Ökten and A. Biyikoğlu, “Development of thermal model for the determination of SLM process parameters,” Optics & Laser Technology, vol. 137, p. 106825, May 2021, doi: 10.1016/j.optlastec.2020.106825.
[7] K. Prem Ananth and N. D. Jayram, “A comprehensive review of 3D printing techniques for biomaterial-based scaffold fabrication in bone tissue engineering,” Annals of 3D Printed Medicine, vol. 13, p. 100141, 2024, doi: 10.1016/j.stlm.2023.100141.
[8] A. Shrivastava, S. Anand Kumar, and S. Rao, “A numerical modelling approach for prediction of distortion in LPBF processed Inconel 718,” Materials Today: Proceedings, vol. 44, pp. 4233–4238, 2020, doi: 10.1016/j.matpr.2020.10.538.
[9] C. Yu et al., “Selective laser melting of GH3536 superalloy: Microstructure, mechanical properties, and hydrocyclone manufacturing,” Advanced Powder Materials, vol. 3, no. 1, p. 100134, 2024, doi: 10.1016/j.apmate.2023.100134.
[10] D. Xie et al., “A Review on Distortion and Residual Stress in Additive Manufacturing,” Chinese Journal of Mechanical Engineering: Additive Manufacturing Frontiers, vol. 1, no. 3, p. 100039, 2022, doi: 10.1016/j.cjmeam.2022.100039.
[11] Y. Huang, L. J. Yang, X. Z. Du, and Y. P. Yang, “Finite element analysis of thermal behavior of metal powder during selective laser melting,” International Journal of Thermal Sciences, vol. 104, pp. 146–157, 2016, doi: 10.1016/j.ijthermalsci.2016.01.007.
[12] D. Sarkar, A. Kapil, and A. Sharma, “Advances in computational modeling for laser powder bed fusion additive manufacturing: A comprehensive review of finite element techniques and strategies,” Additive Manufacturing, vol. 85, no. October 2023, p. 104157, 2024, doi: 10.1016/j.addma.2024.104157.
[13] L. Zhuo et al., “Microstructural evolution and performance optimization of SLM-fabricated W/AlSi10Mg composites,” Journal of Alloys and Compounds, vol. 1010, no. October 2024, p. 178317, 2025, doi: 10.1016/j.jallcom.2024.178317.
[14] C. Li et al., “Effect of strontium salt modification on the microstructure and creep properties of SLM-formed SiC/AlSi10Mg composites,” Journal of Materials Research and Technology, vol. 35, no. December 2024, pp. 5455–5463, 2025, doi: 10.1016/j.jmrt.2025.02.194.
[15] C. Zhang, B. Chen, H. M. Li, X. Liu, G. Zhou, and G. Gou, “Propagation characteristics of ultrasonic in SLM manufactured AlSi10Mg,” Ultrasonics, vol. 135, no. June, p. 107134, 2023, doi: 10.1016/j.ultras.2023.107134.
[16] K. Chen, Q. Lu, X. Yong, P. Zhang, H. Yan, and H. Shi, “Process parameter optimization of SLM AlSi10Mg based on Box-Behnken design and experimental study on microstructure and mechanical properties,” Materials Today Communications, vol. 46, no. April, p. 112740, 2025, doi: 10.1016/j.mtcomm.2025.112740.
[17] J. Praneeth, S. Venkatesh, and L. S. Krishn, “Process parameters influence on mechanical properties of AlSi10Mg by SLM,” Materials Today: Proceedings, no. xxxx, 2023, doi: 10.1016/j.matpr.2022.12.222.
[18] M. Pagac et al., “Prediction of model distortion by fem in 3d printing via the selective laser melting of stainless steel aisi 316l,” Applied Sciences (Switzerland), vol. 11, no. 4, pp. 1–16, 2021, doi: 10.3390/app11041656.
[19] F. Günther et al., “Characterization of additively manufactured lumbar interbody fusion cages based on triply periodic minimal surfaces,” Materials Today Communications, vol. 39, no. March, p. 108634, 2024, doi: 10.1016/j.mtcomm.2024.108634.
[20] P. Scheel et al., “Advancing efficiency and reliability in thermal analysis of laser powder-bed fusion,” International Journal of Mechanical Sciences, vol. 260, no. June, p. 108583, 2023, doi: 10.1016/j.ijmecsci.2023.108583.
[21] A. Olleak and Z. Xi, “Efficient LPBF process simulation using finite element modeling with adaptive remeshing for distortions and residual stresses prediction,” Manufacturing Letters, vol. 24, pp. 140–144, 2020, doi: 10.1016/j.mfglet.2020.05.002.
[22] T. Wu, C. Li, F. Sun, P. F. Liu, and H. B. Xia, “Reduction in residual stress and distortion of thin-walled inconel 718 specimens fabricated by selective laser melting: Experiment and numerical simulation,” International Journal of Pressure Vessels and Piping, vol. 212, no. August, 2024, doi: 10.1016/j.ijpvp.2024.105292.
[23] N. Ahmed, I. Barsoum, and R. K. Abu Al-Rub, “Numerical investigation of residual stresses in thin-walled additively manufactured structures from selective laser melting,” Heliyon, vol. 9, no. 9, p. e19385, 2023, doi: 10.1016/j.heliyon.2023.e19385.
[24] R. Zhou, H. Liu, and H. Wang, “Modeling and simulation of metal selective laser melting process: a critical review,” International Journal of Advanced Manufacturing Technology, vol. 121, no. 9–10, pp. 5693–5706, Aug. 2022, doi: 10.1007/S00170-022-09721-Z/METRICS.
[25] M. R. Condruz, T. A. Badea, and A. Paraschiv, “Numerical and experimental investigation on flexural properties of selective laser melting (SLM) manufactured strut lattices structures from Ti-6Al-4V and Inconel 625,” Materials Today Communications, vol. 40, no. August, p. 110150, 2024, doi: 10.1016/j.mtcomm.2024.110150.
[26] A. Yin, W. Yu, W. Zhu, W. Li, V. Ji, and C. Jiang, “Microstructural characterization and wear performance of shot-peened TA15 titanium alloy fabricated by SLM,” Materials Characterization, vol. 209, no. September 2023, p. 113747, 2024, doi: 10.1016/j.matchar.2024.113747.
[27] Z. Jiang, P. Xu, Y. Liang, and Y. Liang, “Deformation effect of melt pool boundaries on the mechanical property anisotropy in the SLM AlSi10Mg,” Materials Today Communications, vol. 36, no. July, p. 106879, 2023, doi: 10.1016/j.mtcomm.2023.106879.
[28] B. Chen et al., “Comparative study on microstructure, mechanical and high temperature oxidation resistant behaviors of SLM IN718 superalloy before and after heat treatment,” Journal of Materials Research and Technology, vol. 31, no. June, pp. 1535–1546, 2024, doi: 10.1016/j.jmrt.2024.06.163.