Abstract
Fused Deposition Modeling (FDM) of AA6061 aluminum alloys faces several critical challenges, including limited parameter control, inefficient thermal debinding, and sintering difficulties associated with oxide formation. These factors hinder the broader adoption of FDM compared to other additive manufacturing (AM) techniques, often resulting in high porosity and suboptimal mechanical performance. In this study, a commercially available AA6061–PLA filament feedstock was processed via fused deposition modeling (FDM), followed by thermal debinding and sintering. The printing parameters, debinding cycle, and sintering profile were systematically optimized to produce dense AA6061 components. The effects of these processing conditions on relative density, microstructure, and mechanical properties were investigated. Optimized printing parameters, combined with a staged thermal treatment, enabled the fabrication of high-density parts with reduced defects. Furthermore, the introduction of a pre-sintering pressing step significantly enhanced the
final properties, achieving a relative density of 88.34% (11.66% porosity), a hardness of 83.67 ± 0.67 HV (n = 3), and a compressive strength of 115 ± 3 MPa (n = 3). Scanning electron microscopy (SEM) revealed a relatively uniform microstructure with a refined pore distribution. These results demonstrate the potential of FDM as a viable and promising approach for producing aluminum components with improved structural and mechanical characteristics, and provide initial forming–microstructure–property relationships for sintered AA6061 fabricated via metal FDM.
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