Selective Laser Melting (SLM) is an attractive Additive Manufacturing (AM) technology for the fabrication of metallic components with complex structures and high performances. This process fulfills the goals of sustainable production by reducing material waste, optimizing product topology, and recycling metallic powder. Aluminum alloys exhibit also sustainable performances being lightweight and recyclable. Al-Si10-Mg alloy is suitable for SLM processing due to its good castability, good strength, wear, and corrosion resistance. However, the laser processing of aluminum alloys to date needs to be optimized. In this study, the authors have analyzed the role of close values of heat input on microstructure and defects (Electron and Optical microscope, DRX analysis), porosity (optical microscope and X-ray tomography), melting pool geometries (both in transversal and longitudinal sections of the samples) and mechanical performance (hardness and tensile test) of Al-Si10-Mg samples. The results have shown that even at very close values of energy density, the microstructure and properties of the samples differ from each other. © 2023 by the authors.

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