Abstract
Wire arc additive manufacturing enables the production of near-net shape large-volume metallic components leveraging an established industrial base of welding and cladding technology and adapting it for layer-wise material deposition. However, the complex relationship between the process parameters and resulting mechanical properties of the components still remains challenging. In case of high-strength Al-Mg-Si aluminum alloys, no commercial filler wires are yet available due the high susceptibility of solidification cracking as well as the necessary efforts to obtain acceptable mechanical properties. To address this need, we evaluated a novel filler wire based on AlMg0.7Si doped with a Ti5B1 master alloy to foster fine equiaxed grains within the deposited metal. The correlation between the process parameters and component quality was examined by analyzing the size and distribution of pores as well as the grain morphology. Furthermore, we evaluated the influence of different post-weld heat treatment strategies to achieve mechanical properties corresponding to the reference wrought material. We demonstrated that fine equiaxed grains in the weld metal reduced the susceptibility of solidification cracking significantly. The novel AlMg0.7Si-TiB (S Al 6063-TiB) filler wire facilitated wire arc additive manufacturing of high-strength aluminum components with mechanical properties that were almost as superior as the corresponding wrought base material.
Highlights
Additive manufacturing plays an import role to foster the transition to more flexible [1]production paradigms and to ensure sustainable manufacturing concepts [2]
wire arc additive manufacturing (WAAM) allows for high deposition rates of several kg/h and a broad variety of metals to be used depending on the availability of corresponding wires that can be utilized for arc welding processes, such as tungsten inert gas welding (TIG) or gas metal arc welding (GMAW)
With respect to the above mentioned needs and potentials of 6xxx filler wires for WAAM applicable for GMAW processes, this paper presents the utilization of a novel filler wire made of AlMg0.7Si (AW 6063) doped with titanium and boron as a grain refiner
Summary
Additive manufacturing plays an import role to foster the transition to more flexible [1]production paradigms and to ensure sustainable manufacturing concepts [2]. Wire arc additive manufacturing (WAAM) allows the near-net shape production of largevolume metallic components by applying an electric arc and a protective shielding gas to melt a filler wire, thereby, enabling a layer-wise material deposition. The benefits of WAAM are more likely to be realized for expensive or difficult-to-machine high performance materials, such as Ti-alloys, Ni-alloys, high-strength steels or aluminum alloys [4]. In this context, high-strength precipitation hardening aluminum alloys (series 2xxx, 6xxx and 7xxx) are characterized by a superior strength-to-weight ratio that offers a wide range of applications from automotive [5], ship and pipeline construction [6] to aviation [7]
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