Investigation of Solid Particle Erosion Wear Behavior of Additively Manufactured AlSi10Mg Alloys Under Cryogenic Conditions

ABSTRACT This study comparatively investigates the solid particle erosion behavior of cast and laser powder bed fusion (LPBF)‐manufactured AlSi10Mg alloys under room‐temperature and cryogenic conditions, including the effect of T6 heat treatment. Erosion tests were conducted according to ASTM G76 using SiC particles (∼350 µm) at 3 bar and six impact angles (15°–90°). For cryogenic tests, specimens were immersed in liquid nitrogen, and erosion experiments were completed, whereas the surface temperature remained below −100°C. Erosion performance was quantified by weight loss, whereas damage mechanisms were characterized using scanning electron microscopy (SEM) and three‐dimensional surface topography. Discrete element method (DEM) simulations were additionally performed to examine particle impact behavior. The results demonstrated a strong dependence of erosion rate on impact angle. LPBF‐manufactured specimens generally exhibited higher erosion resistance than their cast counterparts, whereas the influence of T6 heat treatment depended on the manufacturing route. Conversely, cryogenic conditions generally increased material loss. Surface analyses showed predominantly ductile erosion mechanisms, characterized by cutting, plowing, lip, and crater formation, and localized plastic deformation, with no extensive brittle fracture. These findings demonstrate the combined effects of manufacturing route, heat treatment, and cryogenic exposure on the erosion response of AlSi10Mg.