For the past few decades, Copper alloys have made significant contributions to a variety of industrial applications due to their efficient electrical and thermal conductivity. However, moving mechanical assemblies continues to raise concerns about wear-related mechanical breakdowns on a worldwide scale. Hence, this research focuses on examining the wear parameters such as load, sliding velocity and distance based on the re-melting strategy of the (Laser Powder Bed Fusion) LPBF process. The sliding tests were carried out over a wide range load (15, 25, 35 and 45 N), sliding velocity (1, 1.5, 2 and 2.5 m/s) and sliding distance (1500, 2500, 3500 and 4500 m) with a pin-on-disc configuration. The LPBFed Cu–Cr–Zr alloy coupon was printed with four different re-melting ranges (5, 15, 30 and 45%) and it was explored to minimise the occurrence of un-melted particles and inter-particle gaps. The wear results show that the wear parameters have a positive correlation with the Wear Rate (WR) and co-efficient of friction (COF) and also witnessed that the WR and COF decrease with increasing the re-melting rate. The nano-hardness analysis was compared on the un-melted and spattered particles and the re-melted surface. The results show that the spattered particles possess 35.8% more nano-hardness than the other surface on the Cu alloy coupon printed with a 45% re-melting range. The FE-SEM images of the worn-out surface reveal that un-melted and spattered particles have a major contribution in reducing the wear resistance of the printed Cu alloy coupons.
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