Experimental and Simulation-Based Assessment of Dimensional Accuracy and Thermomechanical Properties of AlSi10Mg Cubes Produced by LPBF

This study examines the dimensional accuracy and thermomechanical behavior of AlSi10Mg cubes (10 × 10 × 10 mm) fabricated using the Laser Powder Bed Fusion (LPBF) method, a widely applied additive manufacturing technique for lightweight alloys. Dimensional accuracy was evaluated experimentally through optical 3D scanning and compared with numerical predictions generated by Simufact Additive, while thermomechanical behavior was analyzed exclusively through simulation. Fabrication was carried out using fixed parameters of 200 W laser power, 0.1 mm spot diameter, and 0.04 mm layer thickness. To investigate process effects, nine volumetric energy density (VED) values ranging from 78.125 to 12.5 J/mm 3 were applied by adjusting scanning speed and hatch spacing. Experimental–numerical comparisons showed error rates of 0.19 % along the x–z axis and 0.07 % along the y–z axis, confirming the predictive accuracy of the simulations. Surface deviation analysis indicated maximum and minimum differences of 0.0416 mm and 0.0371 mm. Thermal residual stresses varied between 79 and 300 MPa, with higher VED values causing stress concentrations in the upper layers. The findings demonstrate that VED strongly influences dimensional stability and stress distribution, highlighting Simufact Additive as a reliable and cost-effective tool for pre-production optimization and process control.