The effect of volumetric energy density on high-temperature dry sliding wear behaviour of 310 stainless steel fabricated by Selective Laser Melting process

• This research aims to address the influence of volumetric energy density on the high temperature (28 °C, 100 °C, 200 °C, and 300 °C) dry sliding wear behavior of selective laser melting fabricated SS 310. • The study focuses on the worn sample wear track mechanism, wear rate, and Coefficient of friction for all temperatures. • The study focuses on the micro-hardness of worn-out samples at all temperatures. • Performance of surface roughness of worn-out samples at all temperatures. • The study focuses on the residual stress of worn-out samples at all temperatures. Austenitic steels are widely applied in aero-engine components because of their exceptional resistance to wear and corrosion at high temperatures. This research examines the high-temperature dry sliding wear properties of additively made austenitic stainless steel (SS 310) at various temperatures (28 °C, 100 °C, 200 °C, and 300 °C). In addition, the study focuses on worn sample microstructure, wear track mechanism, surface roughness, hardness, and residual stress. The experiments were conducted using the Taguchi method to determine the optimal conditions of laser power (230W- 350 W) and scanning speed (700 mm/s-1100 mm/ sec ) for the as-printed specimen regarding wear rate and coefficient of friction (CoF). The CoF increased to 0.8499 at 100 °C, then decreased to 0.5051 at 300 °C under a laser power of 350 W and a scanning speed of 1100 mm/s. Wear resistance improves with rising temperature due to an oxide glaze. For instance, the wear rate and surface roughness at 28 °C are 0.5242 mm 3 /N-m, and 1.29 µm, increasing to 0.7107 mm 3 /N-m, 1.53 µm for 100 °C, 0.7471 mm 3 /N-m, 2.12 µm for 200 °C, 0.9423 mm 3 /N-m, and 2.73 µm for 300 °C. The hardness increases with temperature, with 310.8 HV, 315.9 HV, 308.8 HV, and 299.8 HV, respectively. The worn surfaces were analysed using SEM/EDS analysis. The material's reduced wear rate is attributed to its increased hardness, stable oxide glaze development, cellular subgrains, and stable hierarchical microstructure. Delamination and oxidation wear are common high-temperature wear mechanisms. Surface oxidation at 300 °C leads to adhesive wear and plastic deformation, acting as a lubricant. Post-treating parts at temperatures above 300 °C is crucial for applications requiring wear-resistant stainless steel, suggesting its suitability.