Optimization of Selective Laser Melting Process Parameters for Enhanced Mechanical Properties and Friction Behavior of AlFeSi10Mg Alloy Components

Abstract

This research investigates wear characteristics of an AlFeSi10Mg alloy produced through selective laser melting (SLM), while introducing a layer-by-layer additive process simulation to streamline the SLM printing process, thereby saving time, cost, and material. AM simulation results demonstrate reduced displacement and temperature during SLM printing. The study emphasizes the critical role of build orientation in determining the quality and performance of AM parts. Employing an L16 orthogonal array of Taguchi design experiments, a model is developed for wear characterization. Optimal process parameters are identified for achieving low wear rate, high density, and high hardness. At the optimal condition (T5), wear measurements include a depth of 94 micrometers, a length change of 0.06%, a volume of 1.25 mm³, a velocity of 1674.46 mm/s, a wear rate of 4.97×10-8 mm²/N, a coefficient of 0.04 mm²/N, and a frictional force of 14.1 N. Laser energy density is computed as 150 J/mm³ based on the achieved optimal parameters.