Studies on Tribological Properties of Additive Manufactured AlSi10Mg Alloy by Selective Laser Melting: Effect of Laser Power and Dry Sliding Conditions

Abstract This investigation explored the effect of laser power and dry sliding conditions on the tribological properties of additive-manufactured AlSi10Mg alloy by selective laser melting. Specimens were produced using three energy inputs: 250 W, 300 W, and 350 W. The 300 W sample exhibited a finely refined microstructure with minimal porosity and an X-ray diffraction (XRD) profile closely matching the AlSi10Mg alloy, achieving an optimal balance of properties, 99.88% relative density, and 137.8 HV hardness. Tribological testing on a pin-on-disc setup at room temperature, varying sliding velocity and load, showed wear-rates for the 250 W, 300 W, and 350 W specimens as 0.0096, 0.0062, and 0.0130 mm3/m, respectively, at 1 m/s sliding velocity. Similar trends held at higher sliding velocities. Samples processed at 250 W laser power primarily exhibited adhesive and delamination wear due to inferior densification and coarse microstructure. In contrast, refined structures at 300–350 W suppressed these severe wear modes, promoting more stable abrasive wear. The 300 W sample showed the highest wear resistance (65.1%) and the lowest average coefficient of friction (0.232). Higher laser powers promoted abrasive wear due to an increased prevalence of intermetallic phases like Mg2Si, whereas lower powers tended toward adhesive wear. The constructed wear transition maps offer valuable insights into selecting optimal operating conditions (load and velocity) for AlSi10Mg components in service.