Coefficient of Thermal Expansion of AlSi10Mg, 316L Stainless Steel and Ti6Al4V Alloys Made with Laser Powder Bed Fusion.

Selami Emanet, Edem Honu, Kekeli Agbewornu, Evelyn Quansah, Congyuan Zeng, Patrick Mensah

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Article in Materials (Basel, Switzerland), 2025. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Cited by 1 paper.

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1citing papers in PubMed

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1 citing paper in PubMed.

Effect of Selectively Etched Al-Rich and Si-Rich Microstructures on the Adhesion of Polyimide Coatings to SLM AlSi10Mg.Materials (Basel, Switzerland) · 2026
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6 authors.

Selami EmanetDepartment of Mechanical & Industrial Engineering, Louisiana State University, Baton Rouge, LA 70803, USA.ORCID 0009-0009-8531-4693

Edem HonuDepartment of Mechanical Engineering, Southern University and A&M College, Baton Rouge, LA 70807, USA.

Kekeli AgbewornuDepartment of Mechanical Engineering, Southern University and A&M College, Baton Rouge, LA 70807, USA.ORCID 0009-0005-7131-4220

Evelyn QuansahDepartment of Mechanical Engineering, Southern University and A&M College, Baton Rouge, LA 70807, USA.

Congyuan ZengDepartment of Mechanical Engineering, Southern University and A&M College, Baton Rouge, LA 70807, USA.ORCID 0000-0002-1476-4277

Patrick MensahDepartment of Mechanical Engineering, Southern University and A&M College, Baton Rouge, LA 70807, USA.

Funding

Louisiana Board of Regents LEQSF (2024-27)-RD-A-23US National Science Foundation OIA 1946231US National Science Foundation OIA-2118756

6 · The paper itself

Abstract

This study investigates the coefficient of thermal expansion (CTE) behavior of LPBF-fabricated AlSi10Mg, 316L stainless steel, and Ti-6Al-4V alloys, focusing on the influence of laser power, scanning speed, and annealing. AlSi10Mg exhibits the highest CTE, but its thermal expansion is highly sensitive to porosity and balling defects. 316L stainless steel shows moderate and stable CTE values, with minimal changes after annealing due to its dense microstructure. Ti-6Al-4V has the lowest CTE, with annealing improving expansion. Higher laser power (100 W) improves fusion, reduces porosity, and stabilizes CTE, while lower power (50 W) increases defects, particularly in AlSi10Mg and Ti-6Al-4V. Scanning speed significantly influences porosity, with 0.4 m/s providing an optimal balance between melt efficiency and defect minimization. Annealing enhances CTE uniformity by reducing the lack of fusion defects and refining grain structures, with the greatest improvements seen in low-laser-energy conditions. These findings provide valuable insights for optimizing LPBF parameters to enhance thermal stability and reliability in aerospace, biomedical, and structural applications.

Indexed as

coefficient of thermal expansionlaser powder bed fusionmetal additive manufacturingprocessing parameters

Identifiers

PMID41095302

DOI10.3390/ma18194468

PMCPMC12526433

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