Effects of Thermal Cycling on Wire and Arc Additive Manufacturing of Al-5356 Components

Köhler, Markus; Hensel, Jonas; Dilger, Klaus

doi:10.3390/met10070952

Cited by 39 publications

(35 citation statements)

References 23 publications

(26 reference statements)

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“…The strain hardening response of Al-Mg alloys is significant due to the Portevin–Le Chatelier effect [ 42 ]. The excellent properties of 5000-alloys in WAAM materials were frequently demonstrated in later years, including 5087 [ 26 , 43 ], 5183 [ 44 , 45 , 46 , 47 ] and 5356 [ 48 , 49 , 50 ] with commercial feedstock.…”

Section: Aluminum Alloysmentioning

confidence: 99%

“…The strain hardening response of Al-Mg alloys is significant due to the Portevin-Le Chatelier effect [42]. The excellent properties of 5000-alloys in WAAM materials were frequently demonstrated in later years, including 5087 [26,43], 5183 [44][45][46][47] and 5356 [48][49][50] with commercial feedstock. 6000-series Al-Mg-Si alloys are heat-treatable through precipitation of semicoherent Mg 2 Si β and β -precipitates for increased strength.…”

Section: Aluminum Alloysmentioning

confidence: 99%

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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: Aluminum Alloysmentioning

confidence: 99%

Section: Aluminum Alloysmentioning

confidence: 99%

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

et al. 2021

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“…WAAM is also the AM method used and studied in [2]. This method provides a promising alternative to conventional machining for the production of large structures with a complex geometry, as well as individualized low quantity components using cost-efficient production resources.…”

Section: Contributionsmentioning

confidence: 99%

“…This method provides a promising alternative to conventional machining for the production of large structures with a complex geometry, as well as individualized low quantity components using cost-efficient production resources. The experimental study in [2] describes the effects of thermal cycling on the geometrical and material properties of a WAAM-ed Al-5356 aluminum alloy.…”

Section: Contributionsmentioning

confidence: 99%

Metal Additive Manufacturing—State of the Art 2020

Asnafi

2021

Metals

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“…Martina et al [17] explained the use of the deposition volume to assess bead roughness and investigated the efficiency of various welding techniques and conditions. Köhler et al [18] continuously stacked aluminum wires using WAAM and observed the changes in bead shapes and structures according to the interlayer temperature. As the wire feed and welding speed increased, the layer height decreased and the wall width increased.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of Bead Geometry for Aluminum Parts Fabricated Using Additive Manufacturing-Based Wire-Arc Welding

et al. 2020

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The wire arc additive manufacturing (WAAM) process used to manufacture aluminum parts has a number of variables. This study focuses on the effects of the heat input and the current and voltage ratio on the deposition efficiency. The effects of the heat input and current and voltage ratio (V/A) on the bead geometry were analyzed, depending on the cross-sectional geometry of the deposition layers, for nine different deposition conditions. The deposition efficiency was also analyzed by analyzing the cross-sectional geometry of the thin-wall parts made of aluminum. The heat input range was about 2.7 kJ/cm to 4.5 kJ/cm; the higher the heat input, the higher the deposition efficiency. The maximum deposition efficiency achieved in this study was 76%. The current and voltage ratio was used to quantify the portion of voltage (V) in the total heat input (Q), and the effect on the bead geometry was analyzed. As the portion of voltage in the quasi heat input decreased by about 10%, it was found that the deposition efficiency was decreased by 1% to 3%.

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Effects of Thermal Cycling on Wire and Arc Additive Manufacturing of Al-5356 Components

Cited by 39 publications

References 23 publications

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Metal Additive Manufacturing—State of the Art 2020

Evaluation of Bead Geometry for Aluminum Parts Fabricated Using Additive Manufacturing-Based Wire-Arc Welding

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