A Study On The Mechanical Properties Of Hybrid Parts Manufactured By Forging And Wire Arc Additive Manufacturing

Abstract

Additive manufacturing (AM) processes such as Wire-Arc Additive Manufacturing (WAAM) are highly flexible and particularly suited for manufacturing complex geometries in small batch-sizes. In the case of large batch-sizes, the low production rate of WAAM is a bottleneck, and therefore forming processes with higher production rates are more suitable. However, forming processes such as closed die forging require dedicated tooling and hence lack the flexibility needed to produce product variants. The current study proposes to combine additive manufacturing with forging to form hybrid components with high complexity and acceptable production rates. This is particularly advantageous for parts that are produced in variants. However, the main challenge in achieving a combination of these manufacturing technologies is the design of the process chain, ensuring that the final properties meet the specifications of the part. In this regard, the process sequence of forming followed by WAAM is investigated. The base material EN AW-6082 was formed to a preform by forging, followed by the deposition of different aluminum alloys by WAAM. The evolution of mechanical properties such as hardness and microstructure was analyzed. Based on the experimental observations, strategies to improve the performance of the hybrid components are presented.