Fabrication and Characterization of Wire Arc Additively Manufactured AlSi5 Structures

Kotlarski, Georgi; Ormanova, Maria; Ossenbrink, Ralf; Nikitin, Alexander; Doynov, Nikolay; Valkov, Stefan; Michailov, Vesselin

doi:10.3390/met12111870

Cited by 6 publications

(9 citation statements)

References 33 publications

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“…Using the CMT+P mode results in the formation of dense fibrous eutectics that improve the mechanical properties of the specimen. This was also confirmed by previous research [24]. In addition to this, the corrosion resistance of the manufactured components also increases, which is of high importance for the aircraft and shipbuilding industries.…”

Section: Introductionsupporting

confidence: 89%

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

Kotlarski,

Ormanova,

Nikitin

et al. 2024

Metals

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In the current paper, the correlation between the physical size of additively built wire arc specimens and their structure and properties is studied. For the purpose of this work, two oval shaped specimens of different lengths were manufactured under the same technological conditions. The specimens have a length of 200 mm and 400 mm and will be referred to as L200 and L400. The microstructure of the samples was studied using X-ray diffraction analysis (XRD), optical microscopy, and scanning electron microscopy (SEM). The microhardness, yield strength (YS), and ultimate tensile strength (UTS) were determined and their correlation with the technological conditions of specimen build-up was clarified. The results of the carried out experiments indicated that the crystallographic structure of both specimens is similar. The scanning electron microscopy images show a higher concentration of irregularly shaped micro-pores formed near the edge of the αAl grains in the structure of the L400 specimen compared to the L200 one. An increase in the size of the αAl solid solution grains in the case of the L200 specimen towards its top section was noticed using optical microscopy. A slightly lower magnitude change was noticed concerning the L400 specimen. The increase in the size of the aluminum crystals was determined to be the increasing interpass temperature. Due to the much smaller thermal dissipation capacity of the smaller specimen, the interpass temperature of the same increased faster compared to the larger specimen. All of the above-mentioned factors led to a decrease in the microhardness of the specimens at higher stages of build-up. Since the specimens were deposited using similar layer deposition conditions, the resultant YS and UTS data are also highly comparable.

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Section: Introductionsupporting

confidence: 89%

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

Kotlarski,

Ormanova,

Nikitin

et al. 2024

Metals

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“…Under low TS, more material is deposited on the base plate and the volume of molten pool is enhanced, owing to a high interaction time between plasma jet and substrate (Kotlarski et al, 2022). It retains the liquidity of the molten metal and prevents its spreading, which is favourable for a low contact angle value (Kotlarski et al, 2022;Yin et al, 2020). A similar behavioural pattern is also graphically evident in Figure 13 (a)-(b).…”

Section: Parametric Influence On Contact Angle and Microhardnessmentioning

confidence: 56%

“…But with a further increase in WFS from 7 m/min, both penetration depth and dilution decreases, as excessive heat input promotes bead convexity that reduces material penetration. Similarly, under low TS, the molten pool’s volume and the liquid phase’s lifetime increase (Kotlarski et al , 2022). So the settling time of the deposited bead increases, which gives rise to high penetration depth (Sarathchandra et al , 2020).…”

Section: Resultsmentioning

confidence: 99%

“…Yin et al (2020) reported that bead width and contact angle share an inverse relationship. Under low TS, more material is deposited on the base plate and the volume of molten pool is enhanced, owing to a high interaction time between plasma jet and substrate (Kotlarski et al , 2022). It retains the liquidity of the molten metal and prevents its spreading, which is favourable for a low contact angle value (Kotlarski et al , 2022; Yin et al , 2020).…”

Section: Resultsmentioning

confidence: 99%

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Non-transferring arc and wire additive manufacturing: microstructure, mechanical properties and bulk texture evolution of deposits

Pattanayak,

Sahoo,

Sahoo

et al. 2024

RPJ

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Purpose This study aims to demonstrate a modified wire arc additive manufacturing (AM) named non-transferring arc and wire AM (NTA-WAM). Here, the build plate has no electrical arc attachment, and the system’s arc is ignited between tungsten electrode and filler wire. Design/methodology/approach The effect of various deposition conditions (welding voltage, travel speed and wire feed speed [WFS]) on bead characteristics is studied through response surface methodology (RSM). Under optimum deposition condition, a single-bead and thin-layered part is fabricated and subjected to microstructural, tensile testing and X-ray diffraction study. Moreover, bulk texture analysis has been carried out to illustrate the effect of thermal cycles and tensile-induced deformations on fibre texture evolutions. Findings RSM illustrates WFS as a crucial deposition parameter that suitably monitors bead width, height, penetration depth, dilution, contact angle and microhardness. The ferritic (acicular and polygonal) and lath bainitic microstructure is transformed into ferrite and pearlitic micrographs with increasing deposition layers. It is attributed to a reduced cooling rate with increased depositions. Mechanical testing exhibits high tensile strength and ductility, which is primarily due to compressive residual stress and lattice strain development. In deposits, ϒ-fibre evolution is more resilient due to the continuous recrystallisation process after each successive deposition. Tensile-induced deformation mostly favours ζ and ε-fibre development due to high strain accumulations. Originality/value This modified electrode arrangement in NTA-WAM suitably reduces spatter and bead height deviation. Low penetration depth and dilution denote a reduction in heat input that enhances the cooling rate.

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“…Obtaining a strong joint between titanium and aluminum alloy is a difficult task due to the different thermophysical characteristics of the two materials [3]. Electron beam welding (EBW) is a suitable technology for fabrication of joint between dissimilar materials [4][5][6][7][8]. This method allows the formation of deep welded joints with very high degree of purity.…”

Section: Introductionmentioning

confidence: 99%

Effect of the beam oscillation on the structure and mechanical properties of electron beam welded joints of Ti6Al4V and Al6082-T6 alloys

Kaisheva,

Dunchev,

Anchev

et al. 2024

J. Phys.: Conf. Ser.

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The results of electron beam welding of Ti6Al4V and Al6082-T6 alloys are presented. The influence of electron-beam scanning geometry on the structure and mechanical properties of the welded joint is studied. Two kinds of samples were investigated – the first specimen was welded without beam oscillation and the second one was obtained using an oscillating electron beam following a circular trajectory of scanning with an oscillation radius of 0.2 mm. X-ray diffraction (XRD) method was used for the determination of the phase composition of the welded joints. The microstructure of the welded joints was studied using Scanning electron microscopy (SEM). Energy-dispersive X-ray spectroscopy (EDX) was applied for the chemical composition investigation. Tensile experiments and microhardness measurements were performed to study the mechanical properties of the welded joints. The sample welded without the application of an oscillating beam showed higher values for the yield strength and tensile strength. The values measured for the microhardness within the welded seam are about 450 HV0.05 in both cases. However, the application of a beam oscillation leads to a significant increase in the micro-hardness of the heat affected zone at the Ti-based alloy. The measured values reached 627 HV0.05.

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Fabrication and Characterization of Wire Arc Additively Manufactured AlSi5 Structures

Cited by 6 publications

References 33 publications

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

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

Non-transferring arc and wire additive manufacturing: microstructure, mechanical properties and bulk texture evolution of deposits

Effect of the beam oscillation on the structure and mechanical properties of electron beam welded joints of Ti6Al4V and Al6082-T6 alloys

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