PBF-LB/M Parameter Optimization of AlSi10Mg Specimens to Minimize Surface Roughness and Maximize Effective Conductivity

PBF-LB/M Parameter Optimization of AlSi10Mg Specimens to Minimize Surface Roughness and Maximize Effective Conductivity | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article PBF-LB/M Parameter Optimization of AlSi10Mg Specimens to Minimize Surface Roughness and Maximize Effective Conductivity Sebastian Putz, Stefan Brenner, Vesna Nedeljkovic-Groha, Günther Dollinger, and 1 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7923809/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract Additive manufacturing via laser powder bed fusion (PBF-LB/M) enables the fabrication of complex radio frequency components but leads to increased surface roughness, which reduces the effective electrical conductivity. This study investigates the potential of optimizing surface roughness and therefore the effective electrical conductivity by using different PBF-LB/M parameter sets. A total of 12 cylindrical AlSi10Mg specimens were fabricated with four different process parameter sets. The specimen's surface roughness was measured using laser scanning microscopy. The effective electrical conductivity was determined by measuring the unloaded quality factor of a radio frequency cavity with the specimens mounted inside. The specimens with the lowest surface roughness of approximately 0.11 µm (Rq) exhibit the highest effective conductivity of about 17.4 MS/m. This corresponds to an improvement of up to 16.5 % compared to the other process parameter sets. Therefore, optimizing additive manufacturing process parameters has the potential to improve radio frequency performance and reduce the need for post-processing. These findings support the development of additively manufactured radio frequency components with improved electrical efficiency. Additive Manufacturing Effective Conductivity Surface Roughness Printing Parameters Optimization Radio Frequency Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7923809","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":544616813,"identity":"1ff80b12-18d5-4a32-a1bf-16bf3697ebf3","order_by":0,"name":"Sebastian Putz","email":"","orcid":"","institution":"Bundeswehr University Munich","correspondingAuthor":false,"prefix":"","firstName":"Sebastian","middleName":"","lastName":"Putz","suffix":""},{"id":544616815,"identity":"ed675b53-3acc-4167-82e7-e8ad850de465","order_by":1,"name":"Stefan Brenner","email":"","orcid":"","institution":"Bundeswehr University 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Conductivity","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Additive Manufacturing, Effective Conductivity, Surface Roughness, Printing Parameters Optimization, Radio Frequency","lastPublishedDoi":"10.21203/rs.3.rs-7923809/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7923809/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eAdditive manufacturing via laser powder bed fusion (PBF-LB/M) enables the fabrication of complex radio frequency components but leads to increased surface roughness, which reduces the effective electrical conductivity. This study investigates the potential of optimizing surface roughness and therefore the effective electrical conductivity by using different PBF-LB/M parameter sets. A total of 12 cylindrical AlSi10Mg specimens were fabricated with four different process parameter sets. The specimen's surface roughness was measured using laser scanning microscopy. The effective electrical conductivity was determined by measuring the unloaded quality factor of a radio frequency cavity with the specimens mounted inside. The specimens with the lowest surface roughness of approximately 0.11 \u0026micro;m (Rq) exhibit the highest effective conductivity of about 17.4 MS/m. This corresponds to an improvement of up to 16.5 % compared to the other process parameter sets. Therefore, optimizing additive manufacturing process parameters has the potential to improve radio frequency performance and reduce the need for post-processing. 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