Abstract

Direct Metal Laser Sintering (DMLS) is an additive manufacturing technology gaining popularity due to its ability to produce near net-shaped functional components. As there is a great need to improve the surface quality of DMLS components to upgrade their dynamic properties, an attempt was made to study the influence of process parameters like laser power, scan speed, and overlap rate on the surface quality of DMLS Aluminum alloy (AlSi10Mg) in as-built condition. The optimized process window to generate the best surface quality was achieved using Response Surface Method (RSM). Artificial Neural Network (ANN) modeling is also developed to map the influence of process parameters on surface quality. Conclusively, Scan speed is found to be most influential over surface quality as per the F and P test results. The optimized process parameters for best surface quality (3.52 µm) were 300 W laser power, 600 mm/sec scan speed, and 25% overlap rate. Both RSM and ANN models were accurate in prediction. However, ANN is recorded as superior with the highest coefficient of correlation (R).

The application spectrum of low cost material reinforced metal matrix composites is growing rapidly in various engineering fields due to their superior mechanical properties. In the present study aluminium alloy (AlSi10Mg)

Direct Metal Laser Sintering (DMLS) is an Additive Manufacturing (AM) technique in which the metal powder will be sintered in selected regions as per 3D CAD file in stack manner in order to produce a three dimensional object with less effort, in less possible time and with minimal wastage of metal. In this paper most widely used DMLS metal powders mechanical and corrosion properties were analyzed and the effect of post processes on the material properties were discussed. The objective of the paper is to fuse the works done so far and to identify gaps to identify the key areas of this technology. The promising and successful application of this revolutionary technology in various sectors like biomedical, aerospace and automotive was also discussed based on material behaviour at different operating conditions. This review would help researchers to find challenges in this booming technology. As per the materials point of view future research prospective was suggested in depth in light of present review.