Influence of process-induced microstructure and imperfections on mechanical properties of AlSi12 processed by selective laser melting

•Mechanical properties significantly higher than those of cast material are achieved.•Process costs can be controlled according to the required mechanical properties.•Base plate heating can control the microstructure and quasistatic properties.•Base plate heating also decreases the fatigue scatter by avoiding large-size pores.•Endurance limit was successfully estimated by short-time fatigue tests. Selective laser melting (SLM) offers high potential for manufacturing complex geometries and custom-made parts due to its unique layer-wise production process. A series of samples of AlSi12 have been manufactured by SLM process to study the effect of process parameters and post-build heat treatment on the microstructure and the corresponding mechanical properties. Optical microscope, scanning electron microscope, quasistatic tests, continuous load increase fatigue tests and constant amplitude fatigue tests have been employed for characterization. A remarkable eutectic microstructure, with dendritic width changing with SLM process parameters, has been observed. Relationship between SLM process parameters, resulting microstructure and the consequent changes in mechanical properties has been discussed. Base plate heating has been found critical in controlling the in-process microstructure. Mechanical properties of SLM parts outperform those of conventionally manufactured alloy, and can be varied as per requirement, by altering the build rate, keeping the process costs in control. Fatigue scatter can also be controlled by heating the base plate during the process.