Effect of Deposition Strategies on the Microstructure and Tensile Properties of Wire Arc Additive Manufactured Al-5Si Alloys

Su, Chuanchu; Chen, Xizhang; Konovalov, S. V.; Singh, R. Arvind; Jayalakshmi, S.; Huang, Lei

doi:10.1007/s11665-021-05528-3

Cited by 24 publications

(10 citation statements)

References 24 publications

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“…The grain size played a significant role, and the grain size of the aluminium alloy was mostly dictated by the number of nucleation, which was greatly influenced by the cooling rate [52]. Grain size could be calculated by multiplying the temperature gradient, G, by the solidification rate, R. Furthermore, the greater the measured value, the finer structure was projected to develop [7]. Wei et al [53] demonstrated that when the heat input was reduced from the molten pool boundary, the grain size dropped, slowing the grain dislocations and reinforcing the material.…”

Section: Microstructure Analysismentioning

confidence: 99%

“…Aluminium alloys have received a lot of attention to be manufactured by AM method [7]. As a result, WAAM of aluminium alloys has been extensively researched, including a variety of alloy systems such as aluminium-copper (Al-Cu), aluminium-magnesium (Al-Mg), aluminiumsilicon (Al-Si), aluminium-copper-magnesium (Al-Cu-Mg), and aluminiummagnesium-silicon (Al-Mg-Si) [8].…”

Section: Introductionmentioning

confidence: 99%

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Process and Heat Resources for Wire Arc Additive Manufacturing of Aluminium Alloy ER4043: A Review

Hussein¹,

Ket²,

Rahim³

et al. 2023

JMechE

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The application of wire arc additive manufacturing (WAAM) in manufacturing has raised interest among researchers. In this paper, the introduction of additive manufacturing and wire arc additive manufacturing, various heat resources for WAAM, aluminium alloys, aluminium alloys ER4043, and performance evaluation of WAAM of ER4043 have been discussed in detail based on bead geometry, microstructure, microhardness, and tensile properties as well as the building path strategies, problems, and future directions. Based on this review, aluminium alloy 4043 (ER4043) is an Al-Si alloy frequently employed as a filler wire because it has superior fluidity and significantly fewer flaws in additively built structures. Next, dwell time and cooling efficiency during the WAAM process significantly affect bead geometry. Besides, a finer microstructure can be obtained with a better cooling rate. However, a coarser microstructure is obtained along with the increased deposition height due to heat accumulation and low solidification rate. Heat input is identified as the main cause of porosity, and CMT with a lower heat input is preferable and outperformed GTAW and GMAW in terms of mechanical properties.

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Section: Microstructure Analysismentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Process and Heat Resources for Wire Arc Additive Manufacturing of Aluminium Alloy ER4043: A Review

Hussein¹,

Ket²,

Rahim³

et al. 2023

JMechE

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show abstract

“…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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“…Various influencing variables have to be considered, which have an influence on the weld seam or the WAAM structure [1]. In addition to the deposition strategy [2] and the travel speed [3], the filler material has a major influence on the resulting material structure. The alloy composition of the filler materials used in this process is adjusted in the molten phase, and the resulting semi-finished products (rod material) are subsequently processed into welding wire electrodes.…”

Section: Introductionmentioning

confidence: 99%

Wire electrode of 5754 aluminum modified by PVD-thin film depositions

2023

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Manufacturers of welding wire electrodes for GMAW welding adapt the alloy compositions of welding wire electrodes in order to adjust the weld pool behavior and the properties of the weld. Additively manufactured components in various sizes and with complex structures and multi-axial stress states place diverse demands on the material. The filler wire can significantly influence the material properties. The approach shown here describes the possibility of coating welding wire electrodes by physical vapor deposition, which enables flexible adjustment of the welding material composition. The element content in the weld metal can be adjusted within certain limits via the coating thickness. In the arc, applied thin-film coatings with coating thicknesses < 1 µm pass into the molten phase together with the substrate wire electrode according to ISO 18273—S Al 5754 (AlMg3). Microalloying elements such as TiB2 or Ti added to the weld pool in this way change the composition and thus influence the microstructure in the weld metal. This results in a grain refinement of up to 46%, which in turn has a positive effect on hot cracking susceptibility. PVD-coated welding electrodes also show changes in arc characteristics. With increasing TiB2 layer thickness, the arc length decreases by up to 44%, while the arc current increases. The fusion penetration behavior changes from a narrow finger-shaped to a round fusion penetration.

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Effect of Deposition Strategies on the Microstructure and Tensile Properties of Wire Arc Additive Manufactured Al-5Si Alloys

Cited by 24 publications

References 24 publications

Process and Heat Resources for Wire Arc Additive Manufacturing of Aluminium Alloy ER4043: A Review

Process and Heat Resources for Wire Arc Additive Manufacturing of Aluminium Alloy ER4043: A Review

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Wire electrode of 5754 aluminum modified by PVD-thin film depositions

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