An Experimental Investigation into the Dry Reciprocating Wear Behavior of Additively Manufactured AlSi10Mg Alloys

Direct Metal Laser Sintering (DMLS) is a novel manufacturing method for creating metallic parts from a 3D CAD model. Aluminium alloy (AlSi10Mg), known for its lightweight and strength, is pertinent to the aerospace and automotive sectors. This research investigates the dry sliding wear characteristics of DMLS AlSi10Mg, comparing it with chrome steel and alumina under varying loads (5 N, 10 N, 20 N). Wear morphology was analyzed using scanning electron microscopy with energy dispersive spectroscopy, 3D profilometer, and X-ray diffraction. Results show that friction values ranged from 0.62 to 0.35 for chrome steel and 0.8 to 0.45 for alumina. Wear rates increased with load, notably higher for alumina (74%, 20%, and 33% more than chrome steel at 5 N, 10 N, and 20 N). High wear resistance against chrome steel is due to stable oxide layer prevents direct metallic interaction. Alumina test showed wear mechanisms like adhesion, delamination, and oxidative wear, while chrome steel exhibited adhesion and delamination. Delamination was prominent at higher loads (10–20 N). The study highlights the limitations of AlSi10Mg in applications involving sliding wear against hard counterparts like alumina, emphasizing load and counterpart material considerations for designing durable parts.