Additive Simulation and Process Parameter Optimization for Wear Characterization Development by Selective Laser Melting of AlSi10Mg Alloy

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Number of pages: 103-116
Year-Number: 2022-2

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Abstract

In this research, wear, hardness, and density were investigated of an AlSi10Mg alloy made by selective laser melting (SLM) and also provided this paper layer by layer additive process simulation before the SLM printing process, which saves time, cost, and material. The AM simulation results are considered based on the lower displacement and lower temperature produced in the SLM printing process. The quality and performance of the additive manufactured (AM) parts depends on the build orientation. A model based on an L9 orthogonal array of taguchi design experiments was created to perform the wear characterization. Finally, the optimal process parameter at low wear rate, high density, and high hardness was found at a laser power of 250 W, a scan speed of 500 mm/s, and a hatch distance of 100 µm. The low wear at t5 was 94 micrometres and the frictional force was 14.1 N. The laser energy density was calculated based on the achieved optimal process parameter (t5) as 150 J/mm3. The hardness of the SLM-AlSi10Mg alloy Vickers was measured at 126±5 HV and the achieved density was 99.6% (2.660 g/cm3) with a defect free component.

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