Theses and Dissertations - UTB/UTPA

Date of Award


Document Type


Degree Name

Master of Science (MS)


Manufacturing Engineering

First Advisor

Dr. Jianzhi Li

Second Advisor

Dr. Waseem Haider

Third Advisor

Dr. Rajiv Nambiar


Selective Laser Melting (SLM), an Additive Manufacturing (AM) technology, enables the production of complex structured metal products. Aluminum alloys are used in SLM as high-strength lightweight materials for weight reduction in structural components. Previous investigations report high laser powers (300 W) and slow scanning speeds (500 mm/s) to process aluminum alloys under SLM. This research investigates the SLM processing of Al-Fe alloy by utilizing metastable Al5Fe2 powder system produced by mechanical alloying. Metastable systems are thermodynamically activated with internal energy that can generate an energy shortcut when processing under SLM. The optimum laser power, scan speeds and scan distances were investigated by test series experiments. Results indicate that metastable Al5Fe2 alloy can be processed and stabilized under a 200 W laser scanning and a relative high scanning speed of 1000 mm/s. Thus, the internal energy of metastable powder contributes in reducing laser energy for SLM process for Al alloys.


Copyright 2015 Hugo Eliud Montiel. All Rights Reserved.

Granting Institution

University of Texas-Pan American

Included in

Manufacturing Commons