Characterization of 5356 Aluminum Walls Produced by Wire Arc Additive Manufacturing (WAAM)

Abstract

Wire arc additive manufacturing (WAAM) is renowned for its high deposition rate, enabling the production of large parts. However, the process has challenges such as porosity formation, residual stresses, and cracking when manufacturing aluminum parts. This study focuses on ana-lyzing the porosity of AA5356 walls manufactured using the WAAM process with the Fronius cold metal transfer system (Wels, Austria). The walls were machined to obtain specimens for tensile testing. The study used computed tomography and the tensile test to analyze the specimens’ porosity and its potential relation to tensile strength. The process parameters analyzed were travel speed, cooling time, and path strategy. In conclusion, increasing travel speed and cooling time significantly affects pore diameter due to the lower heat input to the weld zone. Porosity can be reduced when diminishing heat accumulation. The results indicate that an increase in travel speed produces a slight decrease in porosity. Specifically, the total pore volume diminishes from 0.42 to 0.36 mm3 when increasing the travel speed from 700 to 950 mm/min. The ultimate tensile strength and maximum elongation of the ‘back and forth’ strategy are slightly higher than those of the ‘go’ strategy. After tensile testing, the ultimate tensile strength and yield strength did not show any relation to the porosity measured by computed tomography. The percentage of the pore total volume over the measured volume was lower than 0.12% for all the scanned specimens.

Structure Formation and Mechanical Properties of Wire Arc Additively Manufactured Al4043 (AlSi5) Components

“…The data obtained by Salazar-Guapuriche [41] are in agreement with the data obtained in the present work regarding the UTS/HV ratio. Wieczorowski et al [42] have studied the influence of the different time before each subsequent layer's deposition on the mechanical properties of the specimens. They have found that an increase in the wait time results in a decrease in the interpass temperature and the tensile samples' elongation.…”

Enhancment of Wire Arc Additive Manufacturingproduction of Aluminum Part

“…Аналіз останніх досліджень та публікації. Запроваджені сучасні методи вирішення проблем адитивного виробництва з використанням технології електродугового зварювання [1][2][3][4] вказують на те, що проведення автоматизованого друку потребує подальшого вдосконалення. Для покращення якості процесу виробництва використовуються сучасні методи контролю за температурою [5][6][7], проте й вони не є автоматизованими.…”