Abstract
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.
Highlights
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This review provided an insight into these wire arc additive manufacturing (WAAM)-related defects and presented viable solutions to overcome these obstacles
A survey shows that nearly a dozen aluminum alloys are commercially available as WAAM feedstock
Summary
The ASTM standard F2792 defines additive manufacturing (AM) as “The process of joining materials to make objects from 3D model data, usually layer-upon-layer, as opposed to subtractive manufacturing methodologies” [1]. The metal feedstock may be in the form of powder or wire, and available heat sources are laser, electron beam, plasma, and electric arc. The feedstock for deposition is in the form of a wire This material is melted by a heat source, i.e., the electric arc. The marine industry faces increased competition and lower margins, pushing the adaption of additive manufacturing into design and production In this context, WAAM is regarded as being highly suitable for production of large, complex structures such as bulbous bows, rudders, and ship propellers [12]. WAAM is especially appropriate for production of large-volume parts made by costly materials where scrap metal savings are important. For low production volumes with high complexity, WAAM was shown to be superior to casting and CNC milling in terms of cost and greenhouse gas emissions. WAAM is considered a relatively green manufacturing route for specific applications
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