Microstructure-induced anisotropic tribological properties of Sc-Zr modified Al–Mg alloy (Scalmalloy®) produced via laser powder bed fusion process

• Published in: International journal of advanced manufacturing technology 2024, Vol.130 (1-2), p.755-779
• Main Authors: Abdi, Ata, Salehi, Majid Seyed, Fatemi, Seyed Ali, Iuliano, Luca, Saboori, Abdollah
• Format: Article
• Language: English
• Subjects: Additive manufacturing; Advanced manufacturing technologies; Alloys; Aluminum alloys; Aluminum base alloys; Beds (process engineering); CAE) and Design; Coefficient of friction; Computer-Aided Engineering (CAD; Cost control; Design; Engineering; Friction; Grains; Industrial and Production Engineering; Lasers; Load; Magnesium; Mechanical Engineering; Mechanical properties; Media Management; Metal fatigue; Microhardness; Microstructure; Original Article; Powder beds; Powder metallurgy; Scandium; Surface treatment; Tensile strength; Tribology; Wear rate; Wear resistance; Wear tests; Zirconium
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-023-12691-5

In this study, the correlation between the microstructure and tribological performance of Sc and Zr-modified Al–Mg alloy (Scalmalloy®) samples produced via laser powder bed fusion process was evaluated via a dry sliding Pin-on-Disc wear test under different planes, directions, and various normal applied loads. The results revealed a remarkable dependency of wear properties on the as-built microstructure so that different behaviors were observed along the scanning and building planes. The microstructural examination indicated the presence of bi-modal grains and finely shaped equiaxed grains observed in the building and scanning planes, respectively. Increasing the applied loads from 20 to 40 N led to a significant increase in the coefficient of friction (COF) while increasing the load from 40 to 60 N, slightly decreasing the COF for the studied samples. No dependency was found between the COF and the corresponding microstructure at the highest applied load. The anisotropic wear resistance and COF values were predominant at the lowest applied load. Due to tailored as-built microstructural features and different microhardness values, lower wear rates were noticed along the scanning plane for all applied loads. Under the 20 N applied load, however, the worn surface of the scanning plane showed a clearer and smoother surface compared to the building plane surfaces. Ultra-fine equiaxed grains along the scanning plane and columnar grains along the building plane were determined as the main factors creating anisotropic tribological behavior. The outcomes of this study can pave the way toward producing more wear-resistant surfaces and developing components for critical wear applications in as-built conditions with no need for expensive and time-consuming surface treatments.