Comparative Study of Tribological Performance of LPBF-Produced AlSi10Mg and Wrought Al6061T6 Alloys

Abstract The present research provides a comparative evaluation of the tribological behavior of laser powder bed fusion (LPBF)-printed AlSi10Mg alloy produced in different build directions—vertical, horizontal, and inclined (45 deg) in comparison with conventionally wrought Al6061-T6. LPBF allows the fabrication of intricate geometries and tailored microstructures. In the present study, LPBF test samples were produced with optimized process parameters: 400 W laser power, scan speed of 1200 mm/s, scan distance of 0.12 mm, and layer thickness of 40 μm. The pin-on-disc tribometer was used to measure wear-rates and friction coefficients under dry sliding conditions, considering the effects of sliding velocity, load, and track diameter. Findings reveal that LPBF-produced AlSi10Mg has enhanced wear resistance compared to wrought Al6061-T6. Interestingly, build orientation has a pronounced effect on tribological performance; inclined and vertical orientations show improved wear resistance, whereas horizontal orientation and wrought samples demonstrate higher wear loss and inconsistent friction behavior. These results show that LPBF technology presents a feasible option to produce wear-resistant components for high-performance applications. The capability to customize microstructures using build orientation in LPBF processes provides practical guidance in the selection of materials and process optimization in industries under severe service conditions.