Fabrication of high strength-ductility aluminum alloy heterogeneous plates using additive manufacturing and hot rolling process

Abstract

Aluminum alloy heterogeneous plate has great potential applications in automotive, military, aerospace, and other fields due to its excellent mechanical properties and ability to resist ballistic missile penetration. In the present work, a 5356/7A48 aluminum alloy heterogeneous plate with high strength-ductility and excellent interfacial metallurgical bonding strength was prepared using wire-arc additive manufacturing and hot rolling (WAAM+HR) process. The yield strength and ultimate tensile strength were 280.2 MPa and 392.3 MPa, respectively, both of which were between 5356 and 7A48 alloys, but the elongation was excellent, up to 22%. Its excellent comprehensive mechanical properties far exceed those of Al/Al heterogeneous plates reported in previous studies. In addition, compared with traditional clad plates, its fracture displacement is improved by 48.8%, showing remarkably high interlayer bonding strength. The soft layer 5356 and the hard layer 7A48 beared the main plastic strain and normal stress respectively, resulting in back-stress strengthening at the interlayer interface, which was the fundamental reason for the synergistic effect of strength and plasticity. Furthermore, even at the maximum bending angle of 180°, the heterogeneous plate did not show any sign of fracture, thanks to the fact that the outer soft-clad layer accommodated most of the bending deformation. The heterogeneous lamella structure, high constraint of hard layer to soft layer, and high geometrically necessary dislocations (GNDs) density of interfaces effectively stimulated the back stress strengthening and dislocation hardening, so that the 5356/7A48 aluminum alloy heterogeneous plate exhibited excellent comprehensive mechanical properties. The proposed WAAM+HR process provides an approach for the preparation of multi-functional heterogeneous plates with high strength-ductility and superior bonding strength.