An Experimental Investigation on the Mechanical and Wear Responses of Lightweight AlSi10Mg Components Produced by Selective Laser Melting: Effects of Building Direction and Test Force

Abstract

Additive manufacturing (AM) technology is a game-changer that allows one to produce parts with intricate geometry that have high specific strength despite having low weight. In this study, the wear behavior of parts produced with powder bed fusion at different building directions (horizontal, inclined, and vertical) was examined under different test forces (1, 5, and 10 N). Additionally, the mechanical properties of these parts were determined using tensile tests and hardness evaluations. To explore the deformation mechanism, macroscopic and microscopic observations were carried out. The results showed that the horizontal samples exhibited the highest tensile strength, elongation at break, and toughness values. However, these samples also reflected the highest wear when subjected to a 10 N force. The friction coefficient values dropped depending on the rising test forces for all printing angles. Groove-like damage marks stemming from the ploughing style deformation were more remarkable on the sample surfaces as the test force levels went up. Regional severe wear tracks, debris fragments having an abrasive role, and discrete delamination states were ascertained as probable reasons for the lowest wear endurance of the horizontally built samples under the highest test load.