Wear Characterization of AlSi10Mg Alloy Manufactured via Selective Laser Melting Process Optimization and Environmental Effects on 3D-Printed Parts for Aerospace Applications
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Abstract
This research study examines the wear characterization of AlSi10Mg alloy manufcatured via selective laser melting (SLM), a cutting-edge additive manufacturing (AM) development. A simulation of the layer-by-layer AM process was employed to optimize performance and quality by minimizing displacement and temperature deviations. Taguchi L9 orthogonal array design was utilized to determine optimal process parameters, including a laser power of 250 W, a hatch distance of 100 µm and a scan speed of 500 mm/s. These parameters resulted in high-density components with low wear rates and superior hardness. Wear characterization under varied loads, speeds, and durations identified optimal conditions at 20 N, 200 rpm, and 5 minutes, yielding the least wear rate and frictional force. Comparative analysis showed that post-heat-treated SLM AlSi10Mg significantly outperformed conventional Al6061 cast alloys in mechanical properties and wear resistance. Further testing in diverse environmental conditions, including ambient, cryogenic, and elevated temperatures, confirmed exceptional wear performance of AlSi10Mg, particularly in its post-heat-treated state. This research highlights the potential of SLM to produce aerospace-grade components with enhanced wear resistance and mechanical integrity.
