Metal Additive Manufacturing Conference - MAMC 2024

Lightweight design is very closely associated with additive manufacturing. Besides the design possibilities offered by this technology, the material used also plays a key role. Especially in the LPBF process, the production of the powder and the processing of the material is a major challenge. This applies in particular to magnesium alloys as a lightweight material. Due to its low density and good strength and rigidity properties, this material is ideal for lightweight engineering applications. The basis of this paper is a risk assessment (including a detailed FMEA and measures to minimize risks) for the processing and handling of magnesium powder in the LPBF process. As part of the practical tests, several test specimens with existing parameters for AZ91 were printed and their properties (relative density, microstructure and bonding behavior) have been analyzed. By adjusting the alloy composition (improved evaporation characteristics) and optimizing the process (e.g. optimum inert gas flow, platform temperature) and the process parameters, it is possible to process magnesium more economically in the LPBF process. The result of the research activities is the additive manufacturing of a demonstrator component made of magnesium, which in addition to a high relative density (>99%) also has the dimensional accuracy and surface quality typical for the LPBF process.