Effect of laser energy density on the fretting wear behavior of TC4 alloys prepared by selective laser melting (SLM)

Purpose This paper aims to investigate the effect of laser energy density on the fretting wear properties of TC4 alloys prepared by selective laser melting to enhance their service life. Design/methodology/approach The friction test used a ball-to-plane contact structure and simulated the actual working conditions by applying a linear reciprocating motion. In the experiments, the authors prepared TC4 alloys using different laser energy densities and performed fretting wear tests with D = 100 µm on a friction machine, as well as comparative analyses with conventional cast TC4 materials. 3D optical microscope, scanning electron microscopy and energy spectrum x-ray spectrometer were used to analyze the surface morphology and elemental content of the samples. Findings The results indicate that the friction coefficient and wear volume of selective laser melting (SLM)-TC4 are lower than those of cast TC4, demonstrating superior wear resistance. As the laser energy density increases, the grain size of the SLM-TC4 samples gradually coarsens, leading to an initial improvement followed by a decline in friction coefficient and wear resistance. Among the samples, ET3 (42 J/mm³) exhibits the lowest friction coefficient and wear volume, with the friction coefficient ranging from 0.67 to 0.7 and the wear volume being only 9.92% of that of cast TC4. Originality/value The main contribution of this work is to provide a new reference for improving the wear resistance of TC4 prepared by selective laser melting. By studying the effect of different laser energy densities on the wear resistance of TC4, it provides a theoretical basis for the preparation of SLM-TC4 alloys for industrial applications. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-11-2024-0414/