Influence of AlSi10Mg powder aging on the material degradation and its processing in laser powder bed fusion

This study investigates the impact of powder aging on the degradation of AlSi10Mg powder during processing in laser powder bed fusion. Powder aging as result of handling, continuous storage and recycling is a fundamental concern for aluminum alloys as it introduces oxygen to the feedstock material. In this work, the analysis of the powder properties, affected by laser exposure and the aging procedure, showed a change of chemical and morphological characteristics of the powders in virgin and aged conditions. The oxygen content in the powders appeared to have a significant effect on the powders' surface appearance and light absorbance, gradually deteriorating the processability of the powders with the increase of oxygen level. Optical microscopy and X-ray computed tomography were used to analyze the porosity distribution in the printed part samples, identifying the origin, size and location of the pores. A direct relationship between the pore occurrence in final parts and the oxygen content in the powders was observed, revealing a higher degree of porosity in the aged powder sample (6.5%) in comparison with the virgin state (3.16%). The evolution of mechanical properties in the part samples after laser processing and powder aging was also studied, demonstrating a rapid decrease of ultimate tensile strength and elongation from virgin condition to aged. • Change of AlSi10Mg powder properties with aging and laser processing was studied. • Powder aging induced a severe oxygen pick-up and a decrease of laser absorbance. • With the oxygen increase, pore occurrence in printed parts became more frequent. • Depending on powder condition, a notable change of tensile strength was observed.