Impact Angle-Velocity Interactions Governing Solid-Particle Erosion in Laser Powder Bed Fused AlSi10Mg

Area of Science:

• Materials Science
• Mechanical Engineering
• Additive Manufacturing

Background:

• Laser Powder Bed Fusion (LPBF) is a key additive manufacturing technique for AlSi10Mg alloys.
• Understanding the wear behavior of LPBF AlSi10Mg under various conditions is crucial for its application.

Purpose of the Study:

• To investigate the erosive wear performance of LPBF AlSi10Mg alloy.
• To evaluate the influence of different heat treatments (T5, T6, SR, as-built) on wear resistance.
• To analyze the effect of impact angle and velocity on wear mechanisms.

Main Methods:

• Erosive wear testing of AlSi10Mg samples under varied impact angles (30°, 60°, 90°) and velocities (30, 70, 90 m/s).
• Heat treatment of samples to T5, T6, and SR conditions, alongside as-built (AB) samples.
• Scanning Electron Microscopy (SEM) analysis to examine surface morphology and wear mechanisms.

Main Results:

• Erosive wear was most severe at a 30° impact angle, indicating ductile wear dominance.
• Wear rate increased with impact velocity for all conditions.
• T5 heat-treated samples exhibited the lowest wear rate, demonstrating superior resistance.
• T6 and as-built samples showed higher erosion susceptibility with evidence of brittle fracturing.
• SEM analysis revealed differences in surface features, with T5 showing material smearing and T6/AB showing fragmentation.

Conclusions:

• Microstructural stability, alongside hardness, is critical for erosion resistance in LPBF AlSi10Mg.
• Heat treatment, particularly the T5 condition, is vital for optimizing wear resistance in high-impact applications.
• The study provides insights into tailoring LPBF AlSi10Mg properties for enhanced durability.