Wear resistance and microstructure evolution of network-structured Al–Ce–Si–Mg alloy fabricated by laser powder bed fusion

Improving the wear resistance of lightweight aluminum alloys is important for extending the service reliability of components. Laser powder bed fusion ( L -PBF) offers a promising route for fabricating wear-resistant Al alloys through microstructural architecture control. In this study, an Al–Ce–Si–Mg alloy was fabricated by L -PBF, exhibiting a continuous nanoscale Al₁₁Ce₃ network embedded in the α-Al matrix. The as-built Al–Ce–Si–Mg alloy exhibited a lower wear rate than commercial 6061, 7075, and as-cast Al–Ce–Si–Mg alloys under dry reciprocating sliding conditions. By comparing the as-built sample with a spheroidized counterpart containing isolated intermetallic particles, this study demonstrates that the continuous intermetallic network acting as a strengthening skeleton can enhance resistance to plastic deformation and regulate wear-induced microstructure evolution. The network structure changes the subsurface evolution pathway from dynamic recrystallization-dominated grain refinement to boundary-mediated nanolaminated substructure formation during sliding. Micropillar compression further confirmed that the nanolaminated structure in the as-built alloy exhibited much higher yield strength and strain-hardening capacity, thereby helping to stabilize the protective oxide nanocomposite layer and enhance wear resistance. These findings provide a microstructure design strategy for wear-resistant additively manufactured Al alloys.