In-Layer Laser Remelting Effects on Dry Sliding Tribology of Additive Manufactured Ti-6Al-4V ELI Using GLM–RSM Statistical Method

Ti-6Al-4V ELI (Grade 23) fabricated by Laser Powder Bed Fusion (LPBF) exhibits well-known susceptibility to adhesive wear and tribo-oxidation under dry sliding, yet the tribological consequences of in-process laser remelting remain poorly characterized. This study investigates the influence of an in-layer laser scan strategy (single-scan and double-scan), normal forces in the 5–15 N range, and a sliding speed of 0.10–0.20 m·s−1 on the dry sliding tribological response of additive manufactured Ti-6Al-4V ELI. A full factorial experimental design was carried out and the most significant factors and their contributions to the coefficient of friction, specific wear rate, and contact temperature were identified by a statistical method using a general linear model (GLM). The optimal parameters for both of the scan strategies were predicted using a response surface methodology (RSM). Furthermore, to assess the effect of the laser scan strategy and the in-layer remelting on the local mechanical properties, a microscale and nanoscale indentation was carried out. The results show that the normal load was the dominant factor with a contribution of 89.3% for the coefficient of friction, 54% for the specific wear rate, and 40.5% for the temperature. A significant load–scan strategy interaction that governed the wear behavior was detected. The double-scan strategy exhibited higher wear at 5 N but lower wear at 15 N than the single-scan, a counter-intuitive reversal attributed to the load-threshold tribolayer stabilization promoted by the remelting-induced near-surface microstructural modification. The novelty of this study was the setup of a robust GLM–RSM framework for predictive modeling and optimization of additively manufactured surfaces under tribological loading.