scholarly journals Characterisation of a High-Performance Al–Zn–Mg–Cu Alloy Designed for Wire Arc Additive Manufacturing

Materials ◽  
2020 ◽  
Vol 13 (7) ◽  
pp. 1610 ◽  
Author(s):  
Paulo J. Morais ◽  
Bianca Gomes ◽  
Pedro Santos ◽  
Manuel Gomes ◽  
Rudolf Gradinger ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Additive Manufacturing ◽  
High Performance ◽  
Mechanical Performance ◽  
Fluorescence Analysis ◽  
Cold Metal Transfer ◽  
Direction Parallel ◽  
X Ray ◽  
Wire Arc Additive Manufacturing

Ever-increasing demands of industrial manufacturing regarding mechanical properties require the development of novel alloys designed towards the respective manufacturing process. Here, we consider wire arc additive manufacturing. To this end, Al alloys with additions of Zn, Mg and Cu have been designed considering the requirements of good mechanical properties and limited hot cracking susceptibility. The samples were produced using the cold metal transfer pulse advanced (CMT-PADV) technique, known for its ability to produce lower porosity parts with smaller grain size. After material simulations to determine the optimal heat treatment, the samples were solution heat treated, quenched and aged to enhance their mechanical performance. Chemical analysis, mechanical properties and microstructure evolution were evaluated using optical light microscopy, scanning electron microscopy, energy dispersive X-ray spectroscopy, X-ray fluorescence analysis and X-ray radiography, as well as tensile, fatigue and hardness tests. The objective of this research was to evaluate in detail the mechanical properties and microstructure of the newly designed high-performance Al–Zn-based alloy before and after ageing heat treatment. The only defects found in the parts built under optimised conditions were small dispersed porosities, without any visible cracks or lack of fusion. Furthermore, the mechanical properties are superior to those of commercial 7xxx alloys and remarkably independent of the testing direction (parallel or perpendicular to the deposit beads). The presented analyses are very promising regarding additive manufacturing of high-strength aluminium alloys.

Control of humping phenomenon and analyzing mechanical properties of Al–Si wire-arc additive manufacturing fabricated samples using cold metal transfer process

2021 ◽  
pp. 095440622199840
Author(s):  
Yashwant Koli ◽  
N Yuvaraj ◽  
Aravindan Sivanandam ◽  
Vipin
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Heat Input ◽  
Large Scale ◽  
High Deposition Rate ◽  
Bead Geometry ◽  
Layer By Layer ◽  
Cold Metal Transfer ◽  
Geometrical Shapes ◽  
Wire Arc Additive Manufacturing

Nowadays, rapid prototyping is an emerging trend that is followed by industries and auto sector on a large scale which produces intricate geometrical shapes for industrial applications. The wire arc additive manufacturing (WAAM) technique produces large scale industrial products which having intricate geometrical shapes, which is fabricated by layer by layer metal deposition. In this paper, the CMT technique is used to fabricate single-walled WAAM samples. CMT has a high deposition rate, lower thermal heat input and high cladding efficiency characteristics. Humping is a common defect encountered in the WAAM method which not only deteriorates the bead geometry/weld aesthetics but also limits the positional capability in the process. Humping defect also plays a vital role in the reduction of hardness and tensile strength of the fabricated WAAM sample. The humping defect can be controlled by using low heat input parameters which ultimately improves the mechanical properties of WAAM samples. Two types of path planning directions namely uni-directional and bi-directional are adopted in this paper. Results show that the optimum WAAM sample can be achieved by adopting a bi-directional strategy and operating with lower heat input process parameters. This avoids both material wastage and humping defect of the fabricated samples.

scholarly journals Effect of Filler Metal Type on Microstructure and Mechanical Properties of Fabricated NiAl Bronze Alloy Using Wire Arc Additive Manufacturing System

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 513
Author(s):  
Jae Won Kim ◽  
Jae-Deuk Kim ◽  
Jooyoung Cheon ◽  
Changwook Ji
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Additive Manufacturing ◽  
Filler Metal ◽  
Gas Metal Arc Welding ◽  
Metal Wire ◽  
Cold Metal Transfer ◽  
Metal Type ◽  
Cold Metal ◽  
Wire Arc Additive Manufacturing

This study observed the effect of filler metal type on mechanical properties of NAB (NiAl-bronze) material fabricated using wire arc additive manufacturing (WAAM) technology. The selection of filler metal type is must consider the field condition, mechanical properties required by customers, and economics. This study analyzed the bead shape for representative two kind of filler metal types use to maintenance and fabricated a two-dimensional bulk NAB material. The cold metal transfer (CMT) mode of gas metal arc welding (GMAW) was used. For a comparison of mechanical properties, the study obtained three specimens per welding direction from the fabricated bulk NAB material. In the tensile test, the NAB material deposited using filler metal wire A showed higher tensile strength and lower elongation (approx. +71 MPa yield strength, +107.1 MPa ultimate tensile strength, −12.4% elongation) than that deposited with filler metal wire B. The reason is that, a mixture of tangled fine α platelets and dense lamellar eutectoid α + κIII structure with β´ phases was observed in the wall made with filler metal wire A. On the other hand, the wall made with filler metal wire B was dominated by coarse α phases and lamellar eutectoid α + κIII structure in between.

scholarly journals Wire Arc Additive Manufacturing (WAAM) of Aluminum Alloy AlMg5Mn with Energy-Reduced Gas Metal Arc Welding (GMAW)

Materials ◽  
2020 ◽  
Vol 13 (12) ◽  
pp. 2671 ◽  
Author(s):  
Maximilian Gierth ◽  
Philipp Henckell ◽  
Yarop Ali ◽  
Jonas Scholl ◽  
Jean Pierre Bergmann
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Arc Welding ◽  
Energy Input ◽  
Large Scale ◽  
Unit Length ◽  
Gas Metal Arc Welding ◽  
Cold Metal Transfer ◽  
Metal Arc Welding ◽  
Wire Arc Additive Manufacturing

Large-scale aluminum parts are used in aerospace and automotive industries, due to excellent strength, light weight, and the good corrosion resistance of the material. Additive manufacturing processes enable both cost and time savings in the context of component manufacturing. Thereby, wire arc additive manufacturing (WAAM) is particularly suitable for the production of large volume parts due to deposition rates in the range of kilograms per hour. Challenges during the manufacturing process of aluminum alloys, such as porosity or poor mechanical properties, can be overcome by using arc technologies with adaptable energy input. In this study, WAAM of AlMg5Mn alloy was systematically investigated by using the gas metal arc welding (GMAW) process. Herein, correlations between the energy input and the resulting temperature–time-regimes show the effect on resulting microstructure, weld seam irregularities and the mechanical properties of additively manufactured aluminum parts. Therefore, multilayer walls were built layer wise using the cold metal transfer (CMT) process including conventional CMT, CMT advanced and CMT pulse advanced arc modes. These processing strategies were analyzed by means of energy input, whereby the geometrical features of the layers could be controlled as well as the porosity to area portion to below 1% in the WAAM parts. Furthermore, the investigations show the that mechanical properties like tensile strength and material hardness can be adapted throughout the energy input per unit length significantly.

scholarly journals Microstructure and Mechanical Properties of AlSi7Mg0.6 Aluminum Alloy Fabricated by Wire and Arc Additive Manufacturing Based on Cold Metal Transfer (WAAM-CMT)

Materials ◽  
2019 ◽  
Vol 12 (16) ◽  
pp. 2525 ◽  
Author(s):  
Qingfeng Yang ◽  
Cunjuan Xia ◽  
Yaqi Deng ◽  
Xianfeng Li ◽  
Haowei Wang
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Additive Manufacturing ◽  
Shape Change ◽  
Rapid Development ◽  
Engineering Application ◽  
Metal Transfer ◽  
Cold Metal Transfer ◽  
Microstructure And Mechanical Properties ◽  
Cold Metal

Wire and arc additive manufacturing based on cold metal transfer (WAAM-CMT) has aroused wide public concern in recent years as one of the most advanced technologies for manufacturing components with complex geometries. However, the microstructure and mechanical properties of the parts fabricated by WAAM-CMT technology mostly are intolerable for engineering application and should be improved necessarily. In this study, heat treatment was proposed to optimize the microstructure and enhance mechanical properties in the case of AlSi7Mg0.6 alloy. After heat treatment, the division between coarse grain zone and fine grain zone of as-deposited samples seemed to disappear and the distribution of Si and Mg elements was more uniform. What is more, the yield strength and ultimate tensile strength were improved significantly, while the ductility could be sustained after heat treatment. The improvement of strength is attributed to precipitation strengthening, and the shape change of Si phase. No reduction in ductility is due to the higher work hardening rate caused by nanostructured precipitate. It is proved that heat treatment as an effective method can control the microstructure and enhance comprehensive mechanical properties, which will boost rapid development of WAAM industrial technology.

scholarly journals Wire-arc additive manufacturing of Al-Mg alloy using CMT and PMC technologies

2018 ◽  
Vol 233 ◽  
pp. 00031 ◽  
Author(s):  
Bianca F. Gomes ◽  
Paulo J. Morais ◽  
Vítor Ferreira ◽  
Margarida Pinto ◽  
Luiz H. de Almeida
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Raw Materials ◽  
Industrial Applications ◽  
The Other ◽  
Mg Alloy ◽  
Cold Metal Transfer ◽  
Small Pore ◽  
Wire Arc Additive Manufacturing ◽  
Pore Fraction

Among the several metallic additive manufacturing (MAM) technologies available, the wire-and-arc based ones are very beneficial due to the lower operational costs, higher efficiency use of raw materials, and high deposition rates achieved. The Cold Metal Transfer (CMT) process stands out by the lower heat input compared to the other wire-and-arc based methods. On the other hand, processes such as Pulse Multi Control (PMC) and its variants have not been tested yet in additive manufacturing and for this reason they should be evaluated. Therefore, considering the technologies potential and the need of automotive and aeronautical industry of manufacturing parts of complex and optimized geometry in a faster way, the study of these technologies is very relevant. Thus, the objective of this paper is the additive manufacturing of walls with Al-Mg alloy using CMT, CMT-Pulse, PMC, PMC-Mix, and MIG-Pulse, and the evaluation of the hardness, mechanical strength, and porosity of the manufactured parts aiming future industrial applications. The results showed good mechanical properties, small pore fraction, and geometric uniformity of parts produced with PMC and PMC-Mix. MIG-Pulse and PMC parts presented the smaller pore fraction among the GMAW variants, although no difference was noticed in the mechanical properties of the parts.

scholarly journals Influence of wire arc additive manufacturing of Ti-6Al-4V on microstructure and mechanical properties for potential large-scale aviation parts

2020 ◽  
Vol 321 ◽  
pp. 03037
Author(s):  
D. Elitzer ◽  
H.W. Höppel ◽  
M. Göken ◽  
D. Baier ◽  
C. Fuchs ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Additive Manufacturing ◽  
Mechanical Strength ◽  
Large Scale ◽  
Solution Treatment ◽  
Compression Tests ◽  
Process Gas ◽  
Relationship Of ◽  
Wire Arc Additive Manufacturing

As one of the most common Titanium alloys, Ti-6Al-4V faces new challenges concerning the ecological footprint. Due to the current processes, a high metal chip pollution leads to a Buy-to-Fly of 25:1. In this study the parameter / microstructure relationship of Ti-64 on the mechanical properties are discussed. Wire Arc Additive Manufacturing (WAAM) was applied to build samples for microstructural analyses and compression tests. A stress relief (SR) and a solution treatment and annealing (STA) was performed. It was found that SR had no influence on multi-layered samples due to intrinsic heat-treatment. A STA heat-treatment led to a reduction in the mechanical strength. Helium as process gas resulted in an increased mechanical strength due to higher heat capacity compared to argon.

scholarly journals Correlations between Microstructure Characteristics and Mechanical Properties in 5183 Aluminium Alloy Fabricated by Wire-Arc Additive Manufacturing with Different Arc Modes

Materials ◽  
2018 ◽  
Vol 11 (11) ◽  
pp. 2075 ◽  
Author(s):  
Xuewei Fang ◽  
Lijuan Zhang ◽  
Guopeng Chen ◽  
Xiaofeng Dang ◽  
Ke Huang ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Additive Manufacturing ◽  
Aluminium Alloy ◽  
Cold Metal Transfer ◽  
Average Pore ◽  
Microstructure Characteristics ◽  
The Difference ◽  
Cold Metal ◽  
Wire Arc Additive Manufacturing

The effect of arc modes on the microstructure and tensile properties of 5183 aluminium alloy fabricated by cold metal transfer (CMT) processes has been thoroughly investigated. Heat inputs of CMT processes with three arc modes, i.e., CMT, CMT advance (CMT+A), and CMT pulse (CMT+P), were quantified, and their influence on the formation of pores were investigated. The highest tensile strength was found from samples built by the CMT+A process. This agrees well with their smallest average pore sizes. Average tensile strengths of CMT+A arc mode-built samples were 296.9 MPa and 291.8 MPa along the horizontal and vertical directions, respectively. The difference of tensile strength along the horizontal and vertical directions of the CMT+P and CMT samples was mainly caused by the pores at the interfaces between each deposited layer. The successfully built large 5183 aluminium parts by the CMT+A arc mode further proves that this arc mode is a suitable mode for manufacturing of 5183 aluminium alloy.

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