Wear characteristics of additively manufactured AlSi10Mg against EN-31 and silicon carbide abrasive sheet counter bodies using box Behnken design approach

High strength-to-weight ratio materials are used in the automotive and aerospace industries, and AlSi10Mg is suitable for those applications. The research aims to compare and investigate the wear characteristics of selective laser melted AlSi10Mg pin against two counter bodies, EN-31 hardened steel, and silicon carbide abrasive sheet. The wear rate of additively manufactured AlSi10Mg pin at 0° building orientation was investigated using the box Behnken design approach to identify the suitable wear parameters with the pin on the disc testing facility. Based on analysis of variance, the interaction of load with sliding distance significantly influenced the wear rate of AlSi10Mg in both counter body cases. The adhesion and abrasion wear mechanism were observed in AlSi10Mg with EN-31 and silicon carbide abrasive sheet, respectively. The findings reveal the effect of two counter bodies on the SLMed AlSi10Mg wear phenomenon. Finally, severe wear was observed in the AlSi10Mg pin against the silicon carbide counter body.