Optimization Process Parameter on Wear Characterization of Al6061 and AlSi10Mg Alloy Manufactured by Selective Laser Melting

Abstract

In this research, wear optimization, hardness, and density were investigated for an AlSi10Mg alloy made by selective laser melting (SLM), and also an additive SLM process simulation was carried out. 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 for the Al6061 and AlSi10Mg alloys. However, the wear and mechanical properties of the AlSi10Mg alloy showed better results than the 6061-cast alloys. Finally, the optimal process parameters at low wear rate and frictional force were found at a load of 20 N, a sliding speed of 200 rpm, and a time of 5 minutes. The obtained result at optimal parameter a low wear is 90 micrometers, and the frictional force was 3.6 N. The laser energy density was calculated based on the given process parameter as 150 J/mm3. The hardness of the SLM-AlSi10Mg alloy Vickers was measured for AlSi10Mg as 126±5 HV and Al6061 as 98±5 HV because of the very fine microstructure and fine distribution of the Si phase in AlSi10Mg SLM parts. The highest density achieved was 99.6% (2.660 g/cm3) and obtained defect-free components.