Comparative study of microstructure evaluation and mechanical properties of 4043 aluminum alloy fabricated by wire-based additive manufacturing

Miao, Qiuyu; Wu, Dongjiang; Chai, Dongsheng; Yu, Zhan; Bi, Guijun; Niu, Fangyong; Ma, Guangyi

doi:10.1016/j.matdes.2019.108205

Cited by 98 publications

(33 citation statements)

References 52 publications

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“…4043 is the workhorse for arc welding and is used in a range of industries due to the excellent weldability towards a wide range of aluminum alloys. 4043 is consequently heavily studied for WAAM [ 33 , 34 , 35 , 36 , 37 , 38 ]. The high-silicon brazing alloy 4047 was also demonstrated for WAAM applications [ 39 , 40 , 41 ].…”

Section: Aluminum Alloysmentioning

confidence: 99%

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

et al. 2021

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Processing of aluminum alloys by wire arc additive manufacturing (WAAM) gained significant attention from industry and academia in the last decade. With the possibility to create large and relatively complex parts at low investment and operational expenses, WAAM is well-suited for implementation in a range of industries. The process nature involves fusion melting of a feedstock wire by an electric arc where metal droplets are strategically deposited in a layer-by-layer fashion to create the final shape. The inherent fusion and solidification characteristics in WAAM are governing several aspects of the final material, herein process-related defects such as porosity and cracking, microstructure, properties, and performance. Coupled to all mentioned aspects is the alloy composition, which at present is highly restricted for WAAM of aluminum but received considerable attention in later years. This review article describes common quality issues related to WAAM of aluminum, i.e., porosity, residual stresses, and cracking. Measures to combat these challenges are further outlined, with special attention to the alloy composition. The state-of-the-art of aluminum alloy selection and measures to further enhance the performance of aluminum WAAM materials are presented. Strategies for further development of new alloys are discussed, with attention on the importance of reducing crack susceptibility and grain refinement.

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Section: Aluminum Alloysmentioning

confidence: 99%

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

et al. 2021

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“…Wire based additive manufacturing of large thin-walled aluminium structures in the aerospace application has substantial benefits over conventional subtractive methods [83]. Miao et al [77] reported that 4043 Al-Si alloy deposited by laser arc hybrid additive manufacturing (LAHAW) and WAAM. The higher strength and hardness were observed in the LAHAW compared to WAAM.…”

Section: Waam Processed Aluminium Alloysmentioning

confidence: 99%

Assessment of Process, Parameters, Residual Stress Mitigation, Post Treatments and Finite Element Analysis Simulations of Wire Arc Additive Manufacturing Technique

Kumar

Manikandan

2021

Met. Mater. Int.

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Wire arc additive manufacturing (WAAM) technique became an emerging manufacturing technology because of its costeffective in creating large-scale metal parts with moderately high deposition rates. Mainly, WAAM works through the utilization of heat source as an electric arc by melting the metal wire to build the three-dimensional metal parts in a layer-by-layer approach, which may significantly minimize the fabrication costs compared to powder and other additive manufacturing techniques such as laser and electron beam, similarly. This article reviews WAAM processes and methods and gives an exhaustive overview of the residual stresses, microstructures, and material properties of the as-fabricated and post-fabrication treated WAAM components. The typical defects during the fabrication of metal components by the WAAM process are residual stresses, deformity, porosity, and cracking. And also, methods on controlling residual stresses, improving material properties, and effects of post-processing treatments to enhance the part quality fabricated by using the WAAM process are recommended in this review. Finally, the measurement methods of residual stresses in the metal parts and FEA simulations in the WAAM are discussed. FEA simulations provide better insights on moving heat source model, temperature distributions, and residual stresses in the WAAM process. This article concludes that selecting process parameters affects the quality WAAM component during the deposition process. And also, approaches to improving the part quality are proposed. The materials fabrication issues in the WAAM processes were outlined, and the advanced WAMM processes were suggested to obtain high quality and defect-free WAAM parts.

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“…Al 4043 alloy has strong corrosion resistance and is widely utilized as a filler material in welding aluminum, aerospace, and automobile structures [1,2]. It is mainly used for welding aluminum alloys of the 6000 series [3].…”

Section: Introductionmentioning

confidence: 99%

Artificial Intelligence Investigation on (Al‐Si‐Fe) Alloy Reinforced with Nanoceramic Particles by RSM

Kanna¹,

Sundar

Ganesan

et al. 2022

Journal of Nanomaterials

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Al 4043 alloy is extensively used as a filler material for welding aluminum alloys, especially when welding alloys from the Al 6000 series. It is utilized in aerospace and automotive structural components. For longer life in automotive applications, the wear resistance of Al 4043 alloy must be improved. According to research, tungsten carbide has good wear resistance. In this research, Al 4043 alloy is reinforced with varying percentages (1, 3, and 5%) of nano-sized tungsten carbide to increase wear resistance. Taguchi L27 orthogonal array is employed for the wear analysis. The Taguchi signal-to-noise ratio is used to determine the optimal parameters for minimizing wear and coefficient of friction. The regression model and artificial neural network are developed to predict the experimental results. The outcomes of the regression model and artificial neural network are compared to the experimental results to demonstrate both models’ efficacy. A confirmation test was carried out for the optimal process parameter. The result shows that the minimized specific wear rate of 0.12 mm3/Nm, coefficient of friction of 0.01, and frictional force of 1.02 N are achieved at the optimal combination.

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Comparative study of microstructure evaluation and mechanical properties of 4043 aluminum alloy fabricated by wire-based additive manufacturing

Cited by 98 publications

References 52 publications

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Assessment of Process, Parameters, Residual Stress Mitigation, Post Treatments and Finite Element Analysis Simulations of Wire Arc Additive Manufacturing Technique

Artificial Intelligence Investigation on (Al‐Si‐Fe) Alloy Reinforced with Nanoceramic Particles by RSM

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