Defects Characterization of Additively Manufactured A60601RAM2 Alloy
Abstract
The processing of aluminum alloys via Laser Powder Bed Fusion (L-PBF) presents unique challenges due to their tendency to form solidification-related defects such as porosity and lack of fusion. This study focuses on the defect characterization of the A6061-RAM2 alloy, a modified version of AA6061 developed to enhance printability and reduce defect sensitivity in additive manufacturing. Specimens were fabricated using optimized L-PBF parameters, including controlled laser power, scan speed, hatch spacing, and layer thickness, to investigate the influence of process conditions on defect formation. High-resolution X-ray Computed Tomography (XCT) was employed as a non-destructive technique to assess the internal structure of the printed material in three dimensions. The XCT scans enabled detailed visualization and quantification of defect types, sizes, shapes, and spatial distribution throughout the build volume. Image analysis revealed variations in pore morphology and clustering behavior, which were closely associated with processing parameters and thermal gradients during solidification. A comprehensive evaluation of the XCT data allowed for the classification of dominant defect types and the identification of critical regions within the build. These insights were essential for linking process conditions to microstructural quality and for establishing defect tolerances in design and manufacturing workflows. The results demonstrate the critical role of process optimization in minimizing porosity and enhancing the structural integrity of the A6061-RAM2 alloy. This study provides a comprehensive defect profile for the material and establishes XCT as an essential tool for quality control and process development in metal additive manufacturing.
