Metal transfer modes for Wire Arc Additive Manufacturing Al-Mg alloys: Influence of heat input in microstructure and porosity

Aldalur, Eider; Suárez, Alejandro Rosete; Veiga, Fernando

doi:10.1016/j.jmatprotec.2021.117271

Cited by 89 publications

(26 citation statements)

References 26 publications

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“…However, further studies showed that this velocity depends on parameters such as the furnace power, current frequency, crucible geometry, or the crucible location in the furnace relative to the inductor [26,27]. In the present paper, the β l coefficient was determined using the near-surface velocity data from studies by [28,29], in which they were estimated for various metal alloys in experiments carried out in the same melting device [30].…”

Section: Mass Transfer In the Liquid Phasementioning

confidence: 94%

Kinetics of Zinc Evaporation from Aluminium Alloys Melted Using VIM and ISM Technologies

Smalcerz

Węcki²,

Blacha

et al. 2021

Materials

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Using a vacuum during the smelting and refining of alloys removes dissolved gasses, as well as impurities with high vapour pressure. When smelting is carried out in vacuum induction furnaces, the intensification of the discussed processes is achieved by intensive mixing of the bath, as well as an enhanced mass exchange surface (liquid metal surface) due to the formation of a meniscus. This is due to the electromagnetic field applied to the liquid metal. This study reports the removal of zinc from the Al-Zn alloy containing 6.3 wt.%. Zn. The experiments were carried out with the use of two types of metallurgical devices: the VIM and ISM furnaces. For the experiments carried out in the crucible induction furnace, reduction in the operating pressure in the furnace from 1000 Pa to 10 Pa, together with the increase in temperature from 953 K to 1103 K, is accompanied by a decrease in zinc content in the alloy from 6 to 96%, compared with the initial value. Simultaneously, the overall mass transfer coefficient kZn increases from 5.15 × 10−6 to −1.49 × 10−4 ms−1. For the experiments carried out in the furnace with a cold crucible (T = 953 K), a reduction in the operating pressure in the furnace from 1000 Pa to 10 Pa resulted in a decrease in zinc content in the alloy from 18 to 80%, compared with the initial value. For comparison, the experiments carried out in the crucible induction furnace at 953 K showed a reduction in zinc content in the alloy from 6 to 50%, which means that more intense zinc evaporation is seen in the furnace with a cold crucible. Comparison of ISM and VIM technologies in the removal efficiency of the Al-Zn alloy indicates a higher removal efficiency using the first technology, which, using the same conditions, achieves 80% of the removal efficiency of the component.

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Section: Mass Transfer In the Liquid Phasementioning

confidence: 94%

Kinetics of Zinc Evaporation from Aluminium Alloys Melted Using VIM and ISM Technologies

Smalcerz

Węcki²,

Blacha

et al. 2021

Materials

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“…Figure 1 shows the arrangement of the components in the additive manufacturing; the axes on which the symmetry of the zero bead is analyzed are described. The three modes of pulsed GMAW, cold arc, and pulsed AC transfer are compared at 2 wire speeds, 4 and 8 m/min, with 3 ratios, which is considered as the relationship between the travel speed and the wire feed; welding conditions are better described in [28]. Table 2 summarizes the chosen parameters.…”

Section: Experimental Set-upmentioning

confidence: 99%

Effect of the Metal Transfer Mode on the Symmetry of Bead Geometry in WAAM Aluminum

Veiga

Suárez²,

Aldalur³

et al. 2021

Symmetry

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The symmetrical nature in the case of wall fabrication by wire arc additive manufacturing (WAAM) has been observed in the literature, but it has not been studied as a source of knowledge. This paper focuses on the comparative study of three drop transfer methods employing Gas Metal Arc Welding (GMAW) technology, one of the most reported for the manufacture of aluminum alloys. The transfer modes studied are the well-known pulsed GMAW, cold arc, and the newer pulsed AC. The novelty of the last transfer mode is the reversal of the polarity during the preparation phase of the substance for droplet deposition. This study compares the symmetry of zero beads to determine the best parameters and transfer modes for wire arc additive manufacturing of 5 series aluminum. The pulsed transfer modes show values of 0.6 for symmetry ratio, which makes them more interesting strategies than cold arc with a symmetry ratio of 0.5. Furthermore, the methodology proposed in this study can be extrapolated to other materials manufactured with this technology.

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“…In addition, in the new additive manufacturing [11] and welding [12], the heat-affected zone (HAZ) affects the recrystallization behavior of the alloy and the precipitation of β-Mg 2 Al 3 phase. It has become a major research topic.…”

Section: Introductionmentioning

confidence: 99%

Effects of Trace Amounts of Mn, Zr and Sc on the Recrystallization and Corrosion Resistance of Al-5Mg Alloys

et al. 2021

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This study aimed to explore the effects of trace amounts of Mn, Zr, and Sc on the recrystallization behavior and corrosion resistance of Al-5Mg alloys after process annealing by means of alloy design and microstructure analysis of electron backscatter diffraction (EBSD), electron microprobe (EPMA), and electron microscopes (TEM and SEM). The main objective was to obtain alloys with better corrosion resistance. The results show that the fine Al3Zr and Al3Sc precipitated particles were both superior to the MnAl6 particles in inhibiting grain and sub-grain boundary migrations. Therefore, the Zr-containing and Sc-containing alloys were better than the Mn-containing alloy in inhibiting recrystallization. For further comparison, the thermal stability of the Al3Sc particles was better than that of the Al3Zr particles, so the Sc-containing alloy at the high temperature above 350 °C inhibited grain growth better than the Zr-containing alloy. During the recovery stage of the alloy in the recrystallization process, the β-Mg2Al3 phase precipitated on the sub-grain boundary, thus reducing the occurrence of intergranular corrosion. However, in the initial stage of recrystallization, the β-Mg2Al3 phase continuously precipitated on the grain boundary, causing obvious intergranular corrosion. For the Sc-containing alloy, because there was no obvious grain growth stage, the β-Mg2Al3 phase continuously precipitated on the grain boundary, and thereby intergranular corrosion occurred. Therefore, its corrosion resistance was greatly reduced. By contrast, for the alloy containing Mn or Zr, because of obvious grain growth, magnesium atoms aggregated. As a result, the β-Mg2Al3 phase discontinuously precipitated on the grain boundary. The corrosion morphology was local pitting corrosion rather than intergranular corrosion, and thus the corrosion resistance of the alloy was enhanced. As a novelty, this study clearly observed the sensitized precipitation and corrosion morphology of the β-Mg2Al3 phase of Al-5Mg alloy under different recrystallization methods. This will be of benefit to the design of anti-corrosion measures for the future manufacturing and application of Al-5Mg alloy.

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Metal transfer modes for Wire Arc Additive Manufacturing Al-Mg alloys: Influence of heat input in microstructure and porosity

Cited by 89 publications

References 26 publications

Kinetics of Zinc Evaporation from Aluminium Alloys Melted Using VIM and ISM Technologies

Kinetics of Zinc Evaporation from Aluminium Alloys Melted Using VIM and ISM Technologies

Effect of the Metal Transfer Mode on the Symmetry of Bead Geometry in WAAM Aluminum

Effects of Trace Amounts of Mn, Zr and Sc on the Recrystallization and Corrosion Resistance of Al-5Mg Alloys

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