Multi-objective optimization of LPBF manufacturing with Zn-4Al-1Cu alloy for technical applications

Abstract

Cost-utility analyses vary by application. Regarding laser powder bed fusion (LPBF) manufacturing with zinc for technical applications, however, quality, production costs, and sustainability require distinct evaluation. The narrow process window of LPBF with zinc alloys, due to their low melting point, poses challenges, yet dense parts (> 99 %) were successfully produced, albeit with high costs and occasional quality variations. Commercial LPBF manufacturing demands stable processes for consistent quality. A controlled porosity may be acceptable based on specifications. This study presents a multi-objective optimization of LPBF manufacturing with the Zn alloy Z410. We examined the microstructure and pore morphology of 45 test parts, and applied unsupervised machine learning with principal component analysis to evaluate the process parameter space for density, pore size, and shape, creating process maps. The optimal laser parameters were then used to fabricate a demonstrator as proof of concept.