Multi-Material Wire Arc Additive Manufacturing of low and high alloyed aluminium alloys with in-situ material analysis

Hauser, Tobias; Reisch, Raven T.; Seebauer, Stefan; Parasar, Aashirwad; Kamps, Tobias; Casati, Riccardo; Volpp, Jöerg; Kaplan, Alexander

doi:10.1016/j.jmapro.2021.08.005

Cited by 32 publications

(10 citation statements)

References 25 publications

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“…The porosity content (<1%) and scattered cracking events were believed to cause the reduced ductility. Similar performance was reported by Hauser et al for 6060 [134]. A few studies regarding established 2000-series alloys have been reported.…”

Section: Other Alloys For Waamsupporting

confidence: 88%

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: Other Alloys For Waamsupporting

confidence: 88%

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

et al. 2021

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“…The UAM process induced a high strain rate (deformation) and near adiabatic heating on the stacked Al alloy in such a manner that the application of heat treatment (at 580°C for 1 h + water quenching + 180°C for 8 h) on UAM-processed Al alloy did not cause a substantial decline in the X- and Y-strengths [113]. Solid solution formation was facilitated by the higher Mg content in the WAAM-produced 6060 Al alloy to improve the hardness of the alloy [115]. The addition of inoculants (Zr and Sc) to the 7A55 Al alloy during the WAAM processing stage reduced the hot crack susceptibility of the deposited sample [116].…”

Section: Post-processing Treatments Of Al Alloysmentioning

confidence: 99%

Post-processing treatments–microstructure–performance interrelationship of metal additive manufactured aerospace alloys: A review

Ojo

Taban

2023

Materials Science and Technology

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The application of Metal Additive Manufacturing (MAM) in the aerospace industry has been gaining attention. The poor surface quality of parts greatly limits the prospects of MAM-produced parts in the aerospace industry as fatigue performance hinges on a good surface finish and homogeneous microstructure. Post-processing treatments are important to improve the surface quality and the overall performance of MAM-produced parts during static and dynamic loadings. This paper provides a review of the current state of post-processing treatment options for MAM-produced parts. The advances in the post-processing treatments of MAM parts to improve fatigue strength, tensile strength, surface integrity and other properties of parts are reviewed. Future research prospects on metal additive manufacturing of aerospace parts are briefly expounded. Abbreviations: AM: Additive Manufacturing; CMT-WAAM: Cold Metal Transfer-Based Wire Arc Additive Manufacturing; CSD: Cold Spray Deposition; DA: Direct Aging; DED: Directed Energy Deposition; E: Elongation; EBAM: Wire-feed Electron Beam Additive Manufacturing; EBAM Electron Beam Additive Manufacturing; EBSD: Electron Back Scattered Diffraction; FRAM: Friction Rolling Additive Manufacturing; FSAM: Friction Stir Additive Manufacturing; FSP: Friction Stir Processing; HFDB: Hybrid Friction Diffusion Bonding; HIP: Hot Isostatic Pressing; HSA Homogenisation + Solution Treatment + Aging; IFSP: Interlayer Friction Stir Processing; IPF: Inverse Pole Figure; KAM: Kernel Average Misorientation; LAM: Laser Additive Manufacturing Process; LENS: Laser Engineered Net Shaping; LDM: Laser Deposition Manufacturing; L-PBF: Laser Powder Bed Fusion; MAM: Metal Additive Manufacturing; MTFS: Multi-track Multi-layer Friction Surfacing; O-WLAM: Wire Oscillating Laser Additive Manufacturing (O-WLAM); S: Solution Treatment; SA: Solution Treatment + aging; TEM: Transmission Electron Microscope; UAM: Ultrasonic Additive Manufacturing; UTS: Ultimate Tensile Strength; WAAM: Wire Arc Additive Manufacturing; YS: Yield Strength

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“…This process allows a large variety in geometries to be manufactured, including overhangs [15,16]. Furthermore, it can be used for a wide range of materials and also multi-material and functionally graded approaches [17][18][19][20][21][22][23][24][25]. In this case, the manufacturing process could have a significant impact on the properties of the materials that are summarized and shown in [13,26,27] and need to be considered for the prediction of the material properties.…”

Section: Wire and Arc Additive Manufacturingmentioning

confidence: 99%

Wire and Arc Additive Manufacturing of a CoCrFeMoNiV Complex Concentrated Alloy Using Metal-Cored Wire—Process, Properties, and Wear Resistance

et al. 2022

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The field of complex concentrated alloys offers a very large number of variations in alloy composition. The achievable range of properties varies greatly within these variants. The experimental determination of the properties is in many cases laborious. In this work, the possibility of using metal-cored wires to produce sufficient large samples for the determination of the properties using arc-based additive manufacturing or in detail wire and arc additive manufacturing (WAAM) is to be demonstrated by giving an example. In the example, a cored wire is used for the production of a CoCrFeNiMo alloy. In addition to the process parameters used for the additive manufacturing, the mechanical properties of the alloy produced in this way are presented and related to the properties of a cast sample with a similar chemical composition. The characterization of the resulting microstructure and wear resistance will complete this work. It will be shown that it is possible to create additively manufactured structures for a microstructure and a property determination by using metal-cored filler wires in arc-based additive manufacturing. In this case, the additively manufactured structure shows an FCC two-phased microstructure, a yield strength of 534 MPa, and a decent wear resistance.

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Multi-Material Wire Arc Additive Manufacturing of low and high alloyed aluminium alloys with in-situ material analysis

Cited by 32 publications

References 25 publications

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Post-processing treatments–microstructure–performance interrelationship of metal additive manufactured aerospace alloys: A review

Wire and Arc Additive Manufacturing of a CoCrFeMoNiV Complex Concentrated Alloy Using Metal-Cored Wire—Process, Properties, and Wear Resistance

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