Aluminum is one of the most widely used metals globally; however, its pure form has limitations in applications due to its poor mechanical and tribological properties. To address these limitations, methods such as composite fabrication are employed to enhance the tribological performance of aluminum. In this study, pure aluminum and an aluminum/silica nanocomposite were processed using the selective laser melting (SLM) technique, and their wear behavior was eva‎luated under dry and lubricated conditions. The wear test results revealed that adding 1 wt.% nano-silica to aluminum reduced the wear rate by 21% to 28% and shifted the wear mechanism from adhesive to abrasive. Furthermore, it was observed that the friction coefficient remained constant with increasing load and sliding speed during the wear test, attributed to the formation of an oxide layer during the process. The presence of a lubricant further decreased the wear rate of the composite compared to pure aluminum by 25% to 41%, mitigating both adhesive and abrasive wear effects in both materials. Additionally, the formation of a boundary lubrication regime during the wear test resulted in negligible changes in the friction coefficient with increasing load and sliding speed. Finally, the effect of the manufacturing process on pure aluminum was examined, demonstrating that the SLM technique produced a finer and more uniform microstructure, resulting in a lower wear rate compared to the casting method.

علي مالكي , محسن بدرسماي

صالح اكبرزاده , احسان فروزمهر

امين اله محمدي , محسن اصفهانيان