Skip to main content
SpringerLink
Log in

Investigation of the overlapping coefficient impact on the structure and mechanical properties of Al-Mg alloy obtained by wire arc additive manufacturing

重叠系数对电弧增材制造Al-Mg 合金的结构和力学性能的影响

  • Published:
Journal of Central South University Aims and scope Submit manuscript

Abstract

The work is devoted to the study of structural features and mechanical properties of thick-walled samples of Al-Mg alloy got by direct arc growth. This method has attracted particular attention in recent decades, mainly because of its high productivity and low cost. The high productivity of the process makes the wire arc additive manufacturing technology suitable for the production of large wall thicknesses. It is possible to achieve the correct formation of thick-walled elements and to get the specified dimensions by changing the overlap coefficient. It is important to consider that changes in the overlapping coefficient led to changes in size, morphology, as well as the intermetallic distribution, which will affect the mechanical behavior of the samples. The paper considers the features of grain structure formation, phase intermetallic components and their influence on the mechanical properties of thick-walled samples got at different overlapping coefficients. Two types of intermetallic compounds Mg2Si and Al6(Fe, Mn) were identified in the sample. Their size and morphology differ in relation to the overlap coefficient. As a result, the samples demonstrate anisotropy of mechanical properties. The highest values of tensile strength, yield strength and elongation obtained at 0.4 overlapping coefficient and were 319 MPa, 150 MPa and 16.1 %, respectively.

摘要

本文研究了直接电弧生长制备Al-Mg 合金厚壁样品的结构特征和力学性能。由于该制备方法具有高生产率和低成本的优点, 在近几十年来得到了特别的关注。该工艺的高生产率使电弧增材制造适用于生产大壁厚的材料。通过改变重叠系数, 可以实现厚壁零件的准确成形, 并得到指定的尺寸。重叠系数的变化导致材料尺寸、形态以及金属间化合物分布的变化, 并影响其力学行为。本文考虑了不同重叠系数下晶粒结构形成的特征, 金属间化合物成分及厚壁材料力学性能。发现样品中有两种金属间化合物Mg 2 Si 和Al 6 (Fe, Mn), 它们的大小和形态随重叠系数的变化而改变, 从而导致材料力学性能的各向异性。当重叠系数为0.4 时, 其抗拉强度、屈服强度和伸长率均达到最高值, 分别为319 MPa, 150 MPa 和16.1%。

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

References

  1. BUCHANAN C, GARDNER L. Metal 3D printing in construction: A review of methods, research, applications, opportunities and challenges [J]. Engineering Structures, 2019, 180: 332–348. DOI: https://doi.org/10.1016/j.engstruct.2018.11.045.

    Article  Google Scholar 

  2. PAOLINI A, KOLLMANNSBERGER S, RANK E. Additive manufacturing in construction: A review on processes, applications, and digital planning methods [J]. Additive Manufacturing, 2019, 30: 100894. DOI: https://doi.org/10.1016/j.addma.2019.100894.

    Article  Google Scholar 

  3. OLIVEIRA J P, GOUVEIA F M, SANTOS T G. Micro wire and arc additive manufacturing (µ -WAAM) [J]. Additive Manufacturing Letters, 2022, 2: 100032. DOI: https://doi.org/10.1016/j.addlet.2022.100032.

    Article  Google Scholar 

  4. ÇAM G. Prospects of producing aluminum parts by wire arc additive manufacturing (WAAM) [J]. Materials Today: Proceedings, 2022, 62: 77–85. DOI: https://doi.org/10.1016/j.matpr.2022.02.137.

    Google Scholar 

  5. CUNNINGHAM C R, FLYNN J M, SHOKRANI A, et al. Invited review article: Strategies and processes for high quality wire arc additive manufacturing [J]. Additive Manufacturing, 2018, 22: 672–686. DOI: https://doi.org/10.1016/j.addma.2018.06.020.

    Article  Google Scholar 

  6. ANAND M, BISHWAKARMA H, KUMAR N, et al. Fabrication of multilayer thin wall by WAAM technique and investigation of its microstructure and mechanical properties [J]. Materials Today: Proceedings, 2022, 56: 927–930. DOI: https://doi.org/10.1016/j.matpr.2022.02.542.

    Google Scholar 

  7. WANG Yi-ming, XU Xing-wang, ZHAO Zhuang, et al. Coordinated monitoring and control method of deposited layer width and reinforcement in WAAM process [J]. Journal of Manufacturing Processes, 2021, 71: 306–316. DOI: https://doi.org/10.1016/j.jmapro.2021.09.033.

    Article  Google Scholar 

  8. KE W C, OLIVEIRA J P, CONG B Q, et al. Multi-layer deposition mechanism in ultra high-frequency pulsed wire arc additive manufacturing (WAAM) of NiTi shape memory alloys [J]. Additive Manufacturing, 2022, 50: 102513. DOI: https://doi.org/10.1016/j.addma.2021.102513.

    Article  Google Scholar 

  9. XIN Hao-hui, CORREIA J A F O, VELJKOVIC M, et al. Probabilistic strain-fatigue life performance based on stochastic analysis of structural and WAAM-stainless steels [J]. Engineering Failure Analysis, 2021, 127: 105495. DOI: https://doi.org/10.1016/j.engfailanal.2021.105495.

    Article  Google Scholar 

  10. ROMETSCH P A, ZHU Yu-man, WU Xin-hua, et al. Review of high-strength aluminium alloys for additive manufacturing by laser powder bed fusion [J]. Materials & Design, 2022, 219: 110779. DOI: https://doi.org/10.1016/j.matdes.2022.110779.

    Article  Google Scholar 

  11. TSHEPHE T S, AKINWAMIDE S O, OLEVSKY E, et al, Additive manufacturing of titanium-based alloys- A review of methods, properties, challenges, and prospects [J]. Heliyon, 2022, 8(3): e09041. DOI: https://doi.org/10.1016/j.heliyon.2022.e09041.

    Article  Google Scholar 

  12. SHAHWAZ M, NATH P, SEN I. A critical review on the microstructure and mechanical properties correlation of additively manufactured nickel-based superalloys [J]. Journal of Alloys and Compounds, 2022, 907: 164530. DOI: https://doi.org/10.1016/j.jallcom.2022.164530.

    Article  Google Scholar 

  13. ZHANG Di, LIU Ao-bo, YIN Bang-zhao, et al. Additive manufacturing of duplex stainless steels - A critical review [J]. Journal of Manufacturing Processes, 2022, 73: 496–517. DOI: https://doi.org/10.1016/j.jmapro.2021.11.036.

    Article  Google Scholar 

  14. da SILVA L J, SCOTTI F M, FERNANDES D B, et al. Effect of O2 content in argon-based shielding gas on arc wandering in WAAM of aluminum thin walls [J]. CIRP Journal of Manufacturing Science and Technology, 2021, 32: 338–345. DOI: https://doi.org/10.1016/j.cirpj.2021.01.018.

    Article  Google Scholar 

  15. CAMPATELLI G, CAMPANELLA D, BARCELLONA A, et al. Microstructural, mechanical and energy demand characterization of alternative WAAM techniques for Al-alloy parts production [J]. CIRP Journal of Manufacturing Science and Technology, 2020, 31: 492–499. DOI: https://doi.org/10.1016/j.cirpj.2020.08.001.

    Article  Google Scholar 

  16. RODRIGUES T A, DUARTE V R, MIRANDA R M, et al. Ultracold-wire and arc additive manufacturing (UC-WAAM) [J]. Journal of Materials Processing Technology, 2021, 296: 117196. DOI: https://doi.org/10.1016/j.jmatprotec.2021.117196.

    Article  Google Scholar 

  17. WEI Jing-xun, HE Chang-shu, QIE Mo-fan, et al. Microstructure refinement and mechanical properties enhancement of wire-arc additive manufactured 2219 aluminum alloy assisted by interlayer friction stir processing [J]. Vacuum, 2022, 203: 111264. DOI: https://doi.org/10.1016/j.vacuum.2022.111264.

    Article  Google Scholar 

  18. DING Dong-hong, ZHAO Run-zhuo, LU Qing-hua, et al. A shape control strategy for wire arc additive manufacturing of thin-walled aluminium structures with sharp corners [J]. Journal of Manufacturing Processes, 2021, 64: 253–264. DOI: https://doi.org/10.1016/j.jmapro.2021.01.029.

    Article  Google Scholar 

  19. HE Chang-shu, WEI Jing-xun, LI Ying, et al. Improvement of microstructure and fatigue performance of wire-arc additive manufactured 4043 aluminum alloy assisted by interlayer friction stir processing [J]. Journal of Materials Science & Technology, 2023, 133: 183–194. DOI: https://doi.org/10.1016/j.jmst.2022.07.001.

    Article  Google Scholar 

  20. SU Chuan-chu, CHEN Xi-zhang, GAO Chuang, et al. Effect of heat input on microstructure and mechanical properties of Al-Mg alloys fabricated by WAAM [J]. Applied Surface Science, 2019, 486: 431–440. DOI: https://doi.org/10.1016/j.apsusc.2019.04.255.

    Article  Google Scholar 

  21. HORGAR A, FOSTERVOLL H, NYHUS B, et al. Additive manufacturing using WAAM with AA5183 wire [J]. Journal of Materials Processing Technology, 2018, 259: 68–74. DOI: https://doi.org/10.1016/j.jmatprotec.2018.04.014.

    Article  Google Scholar 

  22. SHIMIZU K, BROWN G M, HABAZAKI H, et al, Direct evidence for interfacial enrichment of iron during anodic oxide growth on an Al6Fe phase [J]. Corrosion Science, 1999, 41(9): 1783–1790. DOI: https://doi.org/10.1016/S0010-938X(99)00015-3.

    Article  Google Scholar 

  23. WU Yi-you, ZHANG Tao-mei, CHEN Chao, et al. Microstructure and mechanical property evolution of additive manufactured eutectic Al-2Fe alloy during solidification and aging [J]. Journal of Alloys and Compounds, 2022, 897: 163243. DOI: https://doi.org/10.1016/j.jallcom.2021.163243.

    Article  Google Scholar 

  24. ZHAO Yu-liang, SONG Dong-fu, WANG Hao-liang, et al. Revealing the influence of Fe on Fe-rich phases formation and mechanical properties of cast Al-Mg-Mn-Fe alloys [J]. Journal of Alloys and Compounds, 2022, 901: 163666. DOI: https://doi.org/10.1016/j.jallcom.2022.163666.

    Article  Google Scholar 

  25. GENG Yan-fei, PANCHENKO I, CHEN Xi-zhang, et al. Wire arc additive manufacturing Al-5.0Mg alloy: Microstructures and phase composition [J]. Materials Characterization, 2022, 187: 111875. DOI: https://doi.org/10.1016/j.matchar.2022.111875.

    Article  Google Scholar 

  26. PANCHENKO O, KURUSHKIN D, MUSHNIKOV I, et al. A high-performance WAAM process for Al-Mg-Mn using controlled short-circuiting metal transfer at increased wire feed rate and increased travel speed [J]. Materials & Design, 2020, 195: 109040. DOI: https://doi.org/10.1016/j.matdes.2020.109040.

    Article  Google Scholar 

  27. KANG Jia-rui, LIU Xun, WANG Tian-zhao. The effects of ultrasonic vibration on Portevin-Le Chatelier (PLC) effect and stress-strain behavior in aluminum alloy 2024 [J]. Scripta Materialia, 2023, 224: 115121. DOI: https://doi.org/10.1016/j.scriptamat.2022.115121.

    Article  Google Scholar 

  28. ARANA M, UKAR E, RODRIGUEZ I, et al, Strategies to reduce porosity in Al-Mg WAAM parts and their impact on mechanical properties [J]. Metals, 2021, 11(3): 524. DOI: https://doi.org/10.3390/met11030524.

    Article  Google Scholar 

  29. ZHAO Y, XIAO J, CHEN S J. Comparison of microstructure and mechanical properties of aluminum components manufactured by CMT [J]. Materials Science Forum, 2017, 898: 1318–1324. DOI: https://doi.org/10.4028/www.scientific.net/msf.898.1318.

    Article  Google Scholar 

  30. GIERTH M, HENCKELL P, ALI Y, et al, Wire arc additive manufacturing (WAAM) of aluminum alloy AlMg5Mn with energy-reduced gas metal arc welding (GMAW) [J]. Materials (Basel, Switzerland), 2020, 13(12): 2671. DOI: https://doi.org/10.3390/ma13122671.

    Article  Google Scholar 

  31. KÖHLER M, FIEBIG S, HENSEL J, et al, Wire and arc additive manufacturing of aluminum components [J]. Metals, 2019, 9(5): 608. DOI: https://doi.org/10.3390/met9050608.

    Article  Google Scholar 

  32. ZHAO Yu-liang, SONG Dong-fu, WANG Hao-liang, et al. Revealing the nucleation and growth mechanisms of Fe-rich phases in Al-Cu-Fe (-Si) alloys under the influence of Al-Ti-B [J]. Intermetallics, 2022, 146: 107584. DOI: https://doi.org/10.1016/j.intermet.2022.107584.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. World-Class Research Center “Advanced Digital Technologies”, State Marine Technical University, Saint Petersburg, 190121, Russia

    Volosevich Darya, Nasonovskiy Konstantin, Voropaev Artem, Gushchina Marina, Korsmik Rudolf & Kliimova-Korsmik Olga

  2. Peter the Great Saint-Petersburg Polytechnic University, Saint Petersburg, 195251, Russia

    Kliimova-Korsmik Olga

Authors
  1. Volosevich Darya
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Nasonovskiy Konstantin
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Voropaev Artem
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Gushchina Marina
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Korsmik Rudolf
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Kliimova-Korsmik Olga
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Volosevich Darya.

Additional information

Contributors

Volosevich DARYA provided the conceptualization, investigation, methodology, validation and writing–original draft, review and editing. Nasonovskiy KONSTANTIN provided the conceptualization, methodology, validation and writing–review and editing. Voropaev ARTEM provided the conceptualization, methodology, validation and writing–review and editing. Gushchina MARINA provided the investigation and writing–review and editing. Korsmik RUDOLF provided the writing–review and editing. Klimova-Korsmik OLGA provided the conceptualization, validation and writing–review and editing.

Conflict of interest

Volosevich DARYA, Nasonovskiy KONSTANTIN, Voropaev ARTEM, Gushchina MARINA, Korsmik RUDOLF and Klimova-Korsmik OLGA declare that they have no conflict of interest.

Foundation item

Project(075-15-2022-312) supported by the Ministry of Science and Higher Education of the Russian Federation as part of the World-class Research Center program: Advanced Digital Technologies

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Darya, V., Konstantin, N., Artem, V. et al. Investigation of the overlapping coefficient impact on the structure and mechanical properties of Al-Mg alloy obtained by wire arc additive manufacturing. J. Cent. South Univ. 30, 1075–1085 (2023). https://doi.org/10.1007/s11771-023-5304-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11771-023-5304-x

Key words

关键词

Search

Navigation