Porosity evolution in additively manufactured aluminium alloy during high temperature exposure

Bai, Jintao; Ding, Hua; Gu, Jianglong; Wang, X S; Qiu, Huan

doi:10.1088/1757-899x/167/1/012045

Cited by 32 publications

(20 citation statements)

References 8 publications

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“…In particular, wire arc additive manufacturing (WAAM) with gas metal arc welding (GMAW) is of high interest due to high deposition rates, material efficiency > 90% and the almost unlimited space available [5]. In addition, WAAM offers the possibility to create complex geometries, which allows the production of novel, lightweight structures [6]. Although, the manufactured parts exhibit surface roughness, which requires post processing with subtractive methods [7,8].…”

Section: Introductionmentioning

confidence: 99%

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

et al. 2020

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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.

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Section: Introductionmentioning

confidence: 99%

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

et al. 2020

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“…A small fraction of hydrogen can also exist in supersaturated state due to the rapid solidification in WAAM [ 64 ]. This hydrogen can be precipitated as secondary pores under postdeposition heat treatments [ 65 ].…”

Section: Challenges Related To Aluminium Waammentioning

confidence: 99%

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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“…Zhang et al [24] found that the WAAMfabricated Al-6Mg alloy shows an anisotropic behaviour in terms of tensile strength, ranging from 8% to 27%. The anisotropic behaviour is explained by the presence of pores that are formed in the inter-layer regions [23,24]. From this short literature review, it is seen that the presence of columnar grains and porosity is one of the main sources for the observed anisotropy in WAAM-processed materials.…”

Section: Introductionmentioning

confidence: 95%

“…This typically causes the formation of columnar grains resulting in anisotropic and heterogeneous microstructures [20][21][22]. Furthermore, porosity formation and its non-uniform distribution [23] might also cause anisotropy in WAAMfabricated aluminum alloys [24]. Anisotropic tensile mechanical properties have been extensively reported in the literature for WAAM-fabricated structures [4,25,26], as well as other additive manufactured (AM) parts [20,21].…”

Section: Introductionmentioning

confidence: 99%

Compression Behaviour of Wire + Arc Additive Manufactured Structures

Abbaszadeh

Ventzke

Neto

et al. 2021

Metals

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Increasing demand for producing large-scale metal components via additive manufacturing requires relatively high building rate processes, such as wire + arc additive manufacturing (WAAM). For the industrial implementation of this technology, a throughout understanding of material behaviour is needed. In the present work, structures of Ti-6Al-4V, AA2319 and S355JR steel fabricated by means of WAAM were investigated and compared with respect to their mechanical and microstructural properties, in particular under compression loading. The microstructure of WAAM specimens is assessed by scanning electron microscopy, electron back-scatter diffraction, and optical microscopy. In Ti-6Al-4V, the results show that the presence of the basal and prismatic crystal planes in normal direction lead to an anisotropic behaviour under compression. Although AA2319 shows initially an isotropic plastic behaviour, the directional porosity distribution leads to an anisotropic behaviour at final stages of the compression tests before failure. In S355JR steel, isotropic mechanical behaviour is observed due to the presence of a relatively homogeneous microstructure. Microhardness is related to grain morphology variations, where higher hardness near the inter-layer grain boundaries for Ti-6Al-4V and AA2319 as well as within the refined regions in S355JR steel is observed. In summary, this study analyzes and compares the behaviour of three different materials fabricated by WAAM under compression loading, an important loading condition in mechanical post-processing techniques of WAAM structures, such as rolling. In this regard, the data can also be utilized for future modelling activities in this direction.

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Porosity evolution in additively manufactured aluminium alloy during high temperature exposure

Cited by 32 publications

References 8 publications

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

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

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Compression Behaviour of Wire + Arc Additive Manufactured Structures

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