Effect of Build Orientation and Heat Treatment on Erosion Behavior of Al10SiMg Fabricated Using Laser Powder Bed Fusion

Abstract

Laser Powder Bed Fusion (LPBF) is a form of additive manufacturing that can directly make metal components and has begun to be employed in a variety of industrial situations. Moreover, the erosion characteristics of SLM-produced items have been documented relatively infrequently. In the current work, the erosion behavior of a heat-treated Al-Si-10% Mg alloy generated via laser powder bed fusion (LPBF) has been investigated. The samples were printed in three directions (horizontal (0o), vertical (90o), and inclined (45o) on the build platform using the Direct Metal Laser Sintering (DMLS) system (EOS M 290) machine. Al%Si-10%Mg samples were given treatment (T5, T6). Optical and scanning electron microscopes (SEM) were used to examine the microstructure under both printed and heat-treated conditions. Energy Dispersive Spectroscopy (EDS) and X-ray Diffraction (XRD) were used to investigate the alloy's elemental composition and compound production. The erosion test was executed in each of the three orientations, plus heat-treated samples and as-printed samples. The selected input parameters were impingement angle and flow velocity. The erosion rate was examined and contrasted across orientations for printed and heat-treated conditions to establish the best orientation. The post-eroded surface was analysed using SEM, EDS, and XRD to evaluate possible erosion processes. The key findings were: T5 heat-treated samples sustain well and have the least mass loss; Horizontal (0°) oriented samples undergo less erosion compared to other orientations; T6 heat-treated samples show maximum erosion on printed samples, and hence it is not recommended. T5 heat treatment is proven to be superior in providing high erosion resistance, followed by printed and T6 heat-treatment, respectively. The heat treatment effects are more significant than the orientation effects in determining the erosion resistance of the Al10SiMg alloy. The erosion mechanisms, such as ploughing, melting, and cratering, were identified.