Electric Contact Resistance of 3D-Printed Al5086 Aluminum

Additive manufacturing by Selective Laser Melting (SLM) or, precisely, Laser Powder Bed Fusion (L-PBF), offers new opportunities for producing electrically functional metal components with tailored geometric designs and material properties. In this study, the electrical contact resistance and related properties of 3D-printed samples made from Al5086 aluminum alloy are tested. The benefits of Al5086 include flexibility without cracking, welding ability and exceptional resistance to corrosion in saltwater and industrial environments. This makes it an excellent candidate for power electric applications due to its good electrical conductivity and corrosion resistance. In this study, an analysis is performed to assess the impact of internal volumetric properties and surface parameters on general contact resistance performance. This analysis combines advanced testing procedures and parameter identification of the electric contact resistance model. This study investigates how these parameters affect contact resistance, which is a critical factor in the reliability of electrical devices. Electrical contact resistance was measured using a dedicated test setup that applied consistent pressure and maintained directional alignment. The results show that the printing direction of the samples slightly affects resistance values due to the continuity of current paths along the build direction, likely due to homogenous inter-layer boundaries and mechanical stress distribution. These findings suggest that both print orientation and internal structure must be considered when designing 3D-printed contact elements for electrical applications. Overall, this study demonstrates the feasibility of using L-PBF-fabricated aluminum components in electric applications where both electrical and structural performances are essential.