Functional additive manufacturing with different aluminum alloys

Abstract

This study investigates deposition of different aluminum alloys and the influence of added elements on their mechanical properties. Focusing on wire and arc additive manufacturing (WAAM), this study aimed to address the constraints of conventional fabrication, particularly in the context of multi-material applications. WAAM was utilized for the precise deposition of 5000 series aluminum alloys onto robust 7000 series counterparts, and the results were analyzed to characterize dissimilar aluminum alloy interactions. The deposition process employed an advanced WAAM system equipped with an industrial robot, dual-axis positioner, and cold metal transfer welder, coupled with A5356 wires and A5052/A7075 plates as materials. Controlled manipulation of wire feed speed and torch speed resulted in the formation of 61 layers in a spiral configuration. Elemental analyses, hardness tests, and tensile testing were performed, revealing a distinct transition layer, which indicates an interplay between dissimilar alloys during deposition. Heat treatment interventions not only unveil the recovery of 7000 series alloy hardness but also demonstrate the feasibility of multimaterial parts with enhanced functionalities. The resulting tensile strength surpasses common 5000 series aluminum alloy benchmarks. The study evaluates interfaces under accuracy considerations, highlighting the practical applications of dissimilar aluminum alloy additive manufacturing. The study reveals an intricate interplay of dissimilar aluminum alloys, pushing the boundaries of WAAM applications. The research not only expands the technical understanding of dissimilar aluminum alloys but also provides practical insights into harnessing WAAM's potential for innovative, functional additive manufacturing. We anticipate that the findings can drive advancements in alloy fabrication techniques and has implications for industries reliant on aluminum alloys across diverse applications.

Keywords

• wire and arc additive manufacturing
• directed energy deposition
• dissimilar metal deposition
• aluminum alloy
• mechanical properties
• wire material