Wire-based Laser Metal Deposition Research Articles

Effects of Laser Defocusing on Bead Geometry in Coaxial Titanium Wire-Based Laser Metal Deposition.

Coaxial wire-based laser metal deposition is a versatile and efficient additive process that can achieve a high deposition rate in the manufacturing of complex structures. In this paper, a three-beam coaxial wire system is studied, with particular attention to the effects of deposition height and laser defocusing on the resulting bead geometry. As the deposition standoff distance changes, so does the workpiece illumination proportion, which describes the ratio of energy going directly into the feedstock wire and into the substrate. Single titanium beads are deposited at varying defocus levels and deposition rates and the bead aspect ratio is measured and analyzed. Over the experimental settings, the defocusing level and deposition rate were found to have a significant effect on the resulting bead aspect ratio. As the defocusing level is increased away from the beam convergence plane, the spot size increases and the deposited track is wider and flatter. Process parameters can be used to tune the deposited material to a desired aspect ratio. In coaxial wire deposition, defocusing provides an adjustment mechanism to the distribution of heat between the wire and substrate and has an important impact on the resulting deposit.

Influences of Machine Hammer Peening on Inconel 718 Workpieces Manufactured by Wire-based Laser Metal Deposition

Additive manufacturing techniques, such as laser metal deposition (LMD), have been used to produce complex-shaped workpieces with high accuracy and material utilization. However, the as-built workpieces often suffer from typical defects such as porosity, surface roughness, and tensile residual stresses that may limit their mechanical properties and service life. To overcome these limitations, post-processing steps such as mechanical forming are recommended to improve the material properties. Surface treatment, such as machine hammer peening (MHP), can significantly improve wear resistance and fatigue strength of the additively manufactured workpiece. MHP is a deterministic, high-frequency forming process that can produce smooth surfaces with high compressive residual stresses. It also offers advantages in producing defined surface structures that exhibit friction-reducing properties. However, the influence of MHP process parameters, such as hammer frequency, step over distance, and stroke distance, on the surface integrity of additively manufactured workpieces is still unknown. In the present work, the influence of MHP on Inconel 718 workpieces manufactured by wire-based laser metal deposition (LMD-w) is analyzed. A Design of Experiments (DoE) of LMD-w parameters was employed to manufacture the workpieces. The workpieces with the least typical defects such as cracks and pores were then selected. In the next step, the selected workpieces were post-processed based on a DoE of MHP parameters. To investigate the influences of MHP on the microstructure of the workpieces, the resulting mechanical properties were measured. It was found that for Inconel 718 workpieces manufactured by LMD-w, MHP can significantly improve surface properties by reducing roughness and increasing hardness. Therefore, this study shows that MHP is a promising post-processing technique to enhance the surface integrity and mechanical properties of LMD-w manufactured workpieces.

Initial experiments to regenerate the surface of plasma-facing components by wire-based laser metal deposition

Plasma-facing components (PFC) in nuclear fusion reactors are exposed to demanding conditions during operation. The combination of thermal loads, plasma exposure as well as neutron induced damage and activation limits the number of materials suitable for this application. Due to its properties, tungsten (W) is foreseen as plasma-facing material (PFM) for the future DEMOnstration power plant. It is considered suitable due to its exceptionally high melting point, excellent thermal conductivity, low tritium retention and low erosion resistance during plasma exposure. But even tungsten armored PFCs have a limited lifetime due to, among other factors, surface erosion and the resulting thickness reduction of the armor material.In-situ local deposition of tungsten by means of additive manufacturing (AM) could counteract surface erosion and thus increase the service life span of PFCs. After evaluation of the potential AM processes qualified for this task, the wire-based laser metal deposition (LMD-w) process was selected as the most suitable process. First trials were conducted to examine if it is possible to reliably deposit tungsten onto tungsten substrate using the LMD-w process. In these first studies, single welding beads were generated, and in later experiments, entire layers were created from several welding beads which are arranged next to each other. To ensure reproducibility of the results, the substrate temperature was kept constant. Further experiments aimed at the elimination or minimization of problems such as oxidation, occurrence of balling defects, porosity, cracking, surface waviness and insufficient connection to the substrate. To increase the welding bead quality, the input parameters like laser power, deposition velocity, wire feed rate, inert gas flow, as well as the wire position were optimized. Furthermore, stacking of several layers, as well as the remelting of an already created layer, were carried out and investigated. This study represents the first steps in testing the feasibility of an in-situ surface regeneration concept for PFCs.

Segmentation-based closed-loop layer height control for enhancing stability and dimensional accuracy in wire-based laser metal deposition

Laser metal deposition (LMD) with wire is a versatile additive manufacturing process used for the production of near-net-shape metal components as well as for modification and repair applications. Major advantages of using wire as the feedstock material as opposed to powder include the elimination of hazardous metal dust in the process environment and the lower costs. However, the process is highly sensitive to disturbances and requires a significant effort for parameter tuning. Thus, in order to achieve a stable process as well as defined geometric properties over many layers, dedicated approaches for monitoring and control are essential. In particular, maintaining a constant distance between the workpiece surface and the deposition head is an important prerequisite for process stability. Therefore, in this work, a layer height control system for wire-based LMD was implemented. The objective was to ensure a constant layer height corresponding to the specified height increment even in case of disturbances. Using a laser line scanner, the height profile of the part was obtained after each deposited layer. The weld beads were then divided into small segments to obtain a fully discrete height profile, and the wire feed rate for the next layer was set by an individual controller within each segment. The implemented control system was tested for its effectiveness under different disturbances, whereby significant height differences could be fully compensated within few layers. The developed segmentation approach was found to be an effective method to ensure the dimensional accuracy of LMD components. This work thus constitutes a major contribution to the advancement of fully automated additive manufacturing of metallic components.

Effects of the thermal history on the microstructural and the mechanical properties of stainless steel 316L parts produced by wire-based laser metal deposition

Laser metal deposition with coaxial wire feeding is a novel technology for additively manufacturing near-net-shape metal parts, as well as for repairing and modifying existing components. The microstructure and, thus, the mechanical properties of the deposited material significantly depend on the thermal history of the part, which is influenced by the process parameters and the amount of dissipated heat energy. In order to investigate these correlations, stainless steel 316L samples were produced under different thermal conditions and thoroughly characterized. Solid cuboids were built on a substrate plate at room temperature as well as on a preheated substrate plate. Subsequently, the influence of the different thermal conditions on the melt pool temperatures was evaluated, and the microstructures, the microhardness, and the tensile properties were analyzed. It was found that the mean melt pool temperatures and the primary dendrite arm spacing (PDAS) increased with the build height, while the cooling rates showed an inverse relationship with the build height. The determined PDAS values were correlated with the microhardness profile of the specimens using a Hall-Petch type relationship. An increased heat accumulation in the parts was thereby associated with a coarser microstructure and diminished mechanical properties. The presented results pave the way for tailoring the properties of additively manufactured components to specific requirements.

Progress in the Realization of µ-Brush W for Plasma-Facing Components

During the service life of plasma-facing components, they are exposed to cyclic stationary and transient thermal loads. The former causes thermal fatigue and potentially detachment between the plasma-facing material tungsten and the structural Cu-based materials (divertor) and steel (first wall). The latter causes surface roughening, cracking, or even melting, which could drastically increase the erosion rate. Employing thin flexible W wires (Ww) with a diameter of a few hundred µm can reduce mechanical stresses, and we demonstrated their crack resilience against transient loads within first proof of principle studies. Here, status and future paths towards the large-scale production of such Ww assemblies, including techniques for realizing feasible joints with Cu, steel, or W, are presented. Using wire-based laser metal deposition, we were able to create a homogeneous and shallow infiltration of about 200 µm of the Ww assembly with steel. A high-heat-flux test on such a µ-brush (10 × 10 × 5 mm3 Ww on a ~0.5 mm thick steel layer) using 5 MW/m2 for 2000 cycles was performed without loss of any wire. Microstructural examination after and infrared analysis during the test showed no significant signs of degradation of the joint.

Laser Metal Deposition with Coaxial Wire Feeding for the Automated and Reliable Build-Up of Solid Metal Parts

Due to their outstanding characteristics, additive manufacturing processes are attracting increasing industrial interest. Among these processes, laser metal deposition (LMD) is an innovative technology for the production of metal components. In order to create three-dimensional parts, wire or powder is deposited layer-wise onto a substrate. When wire is used as feedstock, major drawbacks of the powder-based process, such as the low material usage, contamination of the process cell with metal powder, and health or safety issues, can be overcome or even avoided. In addition, recent developments in laser optics allow for a coaxial wire feeding in the center of an annular laser beam. This eliminates the strong directional dependence of the process when feeding the wire laterally. However, wire-based LMD is highly sensitive to process disturbances, which impedes its broader industrial application. Since it is necessary to completely melt the fed wire to achieve a stable process, self-regulating effects such as overspray in powder-based LMD are not present. In contrast to the widely investigated thin walls, the build-up of multi-track solid structures poses a particular challenge. Therefore, process strategies for producing such solid structures are presented in this paper. The experiments were carried out using a laser processing head that enables coaxial wire feeding (CoaxPrinter, Precitec). By systematically varying the lateral overlap between adjacent weld beads, it was shown that an optimum exists at which minimum surface waviness is achieved. Based on this, defect-free multi-layer solid components could be generated in a reproducible manner. During the process, the melt pool temperature was evaluated using a pyrometer. Furthermore, a microscopic examination of the resulting parts was conducted. The results obtained show the need for process monitoring and control, for which a novel and holistic approach has been developed.

Inline Optical Coherence Tomography for Multidirectional Process Monitoring in a Coaxial LMD-w Process

Within additive manufacturing, process stability is still an unsolved challenge. Process instabilities result from the complexity of laser deposition processes and the dependence of the quality of the workpiece on a variety of factors in the process. Because a stable process is dependent on many different factors, permanent precise inline monitoring is required. The suitability of the optical coherence tomography (OCT) measuring system integrated into a wire-based laser metal deposition (LMD-w) process for the task of process control results from its high resolution and high measuring speed, and from coaxial integration into the laser process, which allows for a spatially and temporally resolved representation of the weld bead topography during the process. To realize this, a spectral domain OCT (SD-OCT) system was developed and integrated into the beam path of the process laser. With the aid of suitable optics, circular scanning was realized, which allows for the 3D depth information to be displayed independently of the direction of movement of the processing head and the centrally running wire. OCT makes it possible to detect the process-typical topography deviations caused by process variations and thus paves the way for adaptive process control that could make additive laser processes more reproducible and precise in the future.

On weldability of aerospace grade Al-Cu-Li alloy AA2065 by wire-feed laser metal deposition

Al-Cu-Li alloys exhibit a superior strength to weight ratio, making the alloys attractive for applications within aviation and aerospace. However, their widespread application has been somewhat limited by the challenges associated with porosity and crack formation during welding. The purpose of this study was to evaluate the weldability of aerospace grade Al-Cu-Li alloy AA2065 by wire-based Laser Metal Deposition (LMD) by using a self-produced wire. The influence of selected process parameters on deposition geometry (width, height and deposition depth), porosity, microstructure and hardness were evaluated by producing single tracks on a base plate. Defect-free tracks with minimal porosity could be produced with a laser power of 2700 W, 800 μm spot size and 1 m/min scanning speed, providing an energy density of 5.4 J/mm2. Depending on the desired deposition rate, the wire-feed rate could be varied between 1 and 1.9 m/min. The microstructure of the deposited material consisted of columnar and globular equiaxed grains with a Cu-rich second phase network throughout the deposited material. The results presented in this study show the potential in utilizing wires produced of AA2065 for laser welding and potentially additive manufacturing by wire-based LMD, increasing the possible areas of application for such high-strength, low weight alloys.

FUNDAMENTAL INVESTIGATIONS ON THE MACHINABILITY OF ADDITIVELY MANUFACTURED MULTI-MATERIALS

Additively manufactured multi-materials promise unique combinations of different material properties. However, the machining behavior of these materials is widely unknown. In this study, fundamental investigations on chip formation and morphology, cutting force, workpiece temperature after cutting and surface quality were conducted in orthogonal cutting experiments. Additively manufactured test specimens made out of 316L stainless steel processed by Laser Powder Bed Fusion (LPBF), and the nickel-based alloy Inconel 718 processed by wire-based Laser Metal Deposition (LMD-w) were machined. Investigations were conducted with single- and multi-material combinations as well as porous 316L material. Besides, conventional cast material was machined in order to draw a relative comparison. The results showed significant changes in chip formation and cutting forces between cast and additively manufactured materials, especially for Inconel 718. These differences can be attributed to the changed microstructure and material properties. For two-component multi-materials, the connection area between the materials acted as a defect only to a limited extent. It was shown that the main influence evoke from the cutting direction in relation to the build-up direction of the specimen.

Express Wire Coil Cladding as an Advanced Technology to Accelerate Additive Manufacturing and Coating

Abstract Metal shafts are indispensable components in mobility, energy, and mechanical engineering. In such applications, the shafts need to withstand severe mechanical loads, friction, high temperature, or corrosive media. This is why shafts are often completely made of high-performance alloys. From a technical point of view, coating an inexpensive base shaft with a thin layer of high-performance material is mostly sufficient to ensure its functionality. Adding functional parts such as shoulders or bearing seats by additive manufacturing instead of creating them by subtractive manufacturing is an advantageous approach to increase flexibility and material efficiency. Reliable and economic Additive Manufacturing and coating processes need to be developed further, and laser-based processes such as wire-based laser metal deposition (LMD-w) offer high potential to accomplish this. They can generate a stable metallurgical bond between the base material and the cladding or the added feature without excessively heating the work piece. Due to their low build-up rate, however, LMD processes are not economically competitive with high-speed subtractive technologies such as drilling or turning, which are predominately used for shaft production. Motivated by this challenge, we present an alternative approach that increases the deposition rate for laser-based shaft cladding. Instead of adding the filler wire continuously, wire coils are wound and preplaced on the shaft. In a second step, laser processing while rotating the part generates a metallurgical bond between the wire and the substrate. In this study, several solid and flux-cored wires were analyzed regarding their suitability for this two-step coil winding and LMD process. The results from LMD experiments give an overview of the resulting surface state and of the welded joint quality after deposition. Metallographic cross-sections show low porosity of the deposited layers and small heat-affected zones in the base shaft. Thanks to its good scalability, this innovative two-step process can help strongly increase the build-up rate compared to classic LMD-w.

Experimental and numerical thermo-mechanical analysis of wire-based laser metal deposition of Al-Mg alloys

• Set-up, calibration and experimental validation of numerical LMD heat transfer model. • Sequential mechanical coupling to calculate residual stresses and displacements. • Simulation-based sensitivity study of process conditions on stresses and displacements. A finite element model is employed to perform a sequentially coupled thermo-mechanical analysis for enabling rapid process simulations of temperature fields, residual stresses and distortions for the production of additively manufactured parts via laser metal deposition. Experimental identification of characteristic process features such as temperature distribution, melt pool dimensions and bead geometries were used for the initial built-up and calibration of the model. The addition of material during process simulation is realised through reactivating inactive elements during the transient heat transfer analysis and through reactivating a combination of inactive and quiet elements during the mechanical analysis. The travelling heat source is geometrically bounded to precisely control the volume of its energy distribution. The results of the transient heat transfer analysis are sequentially coupled to a mechanical analysis for obtaining information on the resulting residual stresses and deformation. Based on the good agreement between numerical and experimental results of the thermal analysis, conclusions on the corresponding residual stress distributions and deformation are made. It is shown that the model represents an efficient tool for process prediction regarding thermal history, residual stresses and final-part deformations. Finally, the model is utilised to identify parameters and conditions of the process that lead to reduced residual stresses and deformations of the investigated additive part.

Pulsed Laser Influence on Temperature Distribution during Dual Beam Laser Metal Deposition

Wire-based Laser Metal Deposition (LMD-w) is a suitable manufacturing technology for a wide range of applications such as repairing, coating, or additive manufacturing. Employing a pulsed wave (pw) laser additionally to the continuous wave (cw) process laser has several positive effects on the LMD process stability. The pw-plasma has an influence on the cw-absorption and thus the temperature distribution in the workpiece. In this article, several experiments are described aiming to characterize the heat input during dual beam LMD. In the first setup, small aluminum and steel disks are heated up either by only cw or by combined cw and pw radiation. The absorbed energy is then determined by dropping the samples into water at ambient temperature and measuring the water’s temperature rise. In a second experiment, the temperature distribution in the deposition zone under real process conditions is examined by two-color pyrometer measurements. According to the results, the pw plasma leads to an increase of the effective absorption coefficient by more than 20%. The aim of this work is to achieve a deeper understanding of the physical phenomena acting during dual beam LMD and to deploy them selectively for a better and more flexible process control.

Experimental investigations on the influence of temperature for Laser Metal Deposition with lateral Inconel 718 wire feeding

In the present work, the thermal history influence on Inconel 718 thin-wall structures fabricated by wire-based Laser Metal Deposition (LMD-w) was analyzed. To perform the depositions, a novel processing head with wire force and gas nozzle temperature monitoring was employed. Based on the thermal radiation a temperature threshold for a stable process could be defined. General process trends and typical defects as cracks, pores and lack of fusion are also discussed. Additionally, Scanning Electron Microscope (SEM) images and Energy Dispersive Spectroscopy (EDS) were employed to verify the influences of different cooling rates and the deposition strategy on the microstructure. Finally, to verify the resulting mechanical properties, hardness measurements were performed on each sample. It was found that, for thin-wall fabrication by LMD-w, heat accumulation can adversely affect the build-up. Therefore, cooling of interlayers is suggested as a strategy to mitigate such a problem.

Additive manufacturing using fine wire-based laser metal deposition

PurposeUsing wire as feedstock has several advantages for additive manufacturing (AM) of metal components, which include high deposition rates, efficient material use and low material costs. While the feasibility of wire-feed AM has been demonstrated, the accuracy and surface finish of the produced parts is generally lower than those obtained using powder-bed/-feed AM. The purpose of this study was to develop and investigate the feasibility of a fine wire-based laser metal deposition (FW-LMD) process for producing high-precision metal components with improved resolution, dimensional accuracy and surface finish.Design/methodology/approachThe proposed FW-LMD AM process uses a fine stainless steel wire with a diameter of 100 µm as the additive material and a pulsed Nd:YAG laser as the heat source. The pulsed laser beam generates a melt pool on the substrate into which the fine wire is fed, and upon moving the X–Y stage, a single-pass weld bead is created during solidification that can be laterally and vertically stacked to create a 3D metal component. Process parameters including laser power, pulse duration and stage speed were optimized for the single-pass weld bead. The effect of lateral overlap was studied to ensure low surface roughness of the first layer onto which subsequent layers can be deposited. Multi-layer deposition was also performed and the resulting cross-sectional morphology, microhardness, phase formation, grain growth and tensile strength have been investigated.FindingsAn optimized lateral overlap of about 60-70% results in an average surface roughness of 8-16 µm along all printed directions of the X–Y stage. The single-layer thickness and dimensional accuracy of the proposed FW-LMD process was about 40-80 µm and ±30 µm, respectively. A dense cross-sectional morphology was observed for the multilayer stacking without any visible voids, pores or defects present between the layers. X-ray diffraction confirmed a majority austenite phase with small ferrite phase formation that occurs at the junction of the vertically stacked beads, as confirmed by the electron backscatter diffraction (EBSD) analysis. Tensile tests were performed and an ultimate tensile strength of about 700-750 MPa was observed for all samples. Furthermore, multilayer printing of different shapes with improved surface finish and thin-walled and inclined metal structures with a minimum achievable resolution of about 500 µm was presented.Originality/valueTo the best of the authors’ knowledge, this is the first study to report a directed energy deposition process using a fine metal wire with a diameter of 100 µm and can be a possible solution to improving surface finish and reducing the “stair-stepping” effect that is generally observed for wires with a larger diameter. The AM process proposed in this study can be an attractive alternative for 3D printing of high-precision metal components and can find application for rapid prototyping in a range of industries such as medical and automotive, among others.

Microstructure by design: An approach of grain refinement and isotropy improvement in multi-layer wire-based laser metal deposition

The additive production of metallic components with high-throughput is usually associated with high process temperatures and slow cooling rates. This typically results in strongly oriented columnar grain growth along the building direction of the structure having exceedingly large grain sizes. As a result, such structures show typically low strength and anisotropic mechanical behaviour in as-deposited condition. Consequently, post-processing is commonly performed to homogenize and eventually increase the mechanical properties of the deposited structures. In this regard, precise control of the applied process energy allows a modification of the local temperature distribution and cooling conditions during the additive manufacturing process, which strongly influence the resulting solidification microstructure. The aim of the present study is the development of an approach that allows to influence the solidification conditions in wire-based laser metal deposition of an Al-Mg alloy through specific adjustments of the laser irradiation. It was found that significantly different solidification microstructures in as-deposited condition can be achieved by adjusting the laser beam irradiance within a range resulting in conduction mode welding conditions while keeping the heat input constant. The application of high laser beam irradiances, close to the transition to keyhole mode welding, results in structures with a homogeneous large-grained solidification microstructure exhibiting a degree of anisotropy of around 12% between building direction and the direction of deposition. In contrast, the use of low laser beam irradiance close to the lower limit of stable melting, results in structures with a significantly refined microstructure. Consequently, an increase of yield strength of up to around 20% and microhardness of up to 13%, as compared to structures processed with high laser beam irradiance, could be obtained. Moreover, the anisotropy of the as-deposited structure was reduced to a degree lower than 2%.

Process Optimization of Wire-Based Laser Metal Deposition of Titanium

Titanium alloys are used instead of steel and nickel-based alloys to lower the weight of turbines whenever it is applicable. Due to the high manufacturing costs of titanium, near-net-shape processes like laser metal deposition (LMD) processes are an approach to improve the production of new turbomachinery components. Additionally, these processes are also suitable for repair. LMD uses wire or powder as additional material. When highly reactive materials like titanium grade 5 (Ti6Al4V) are processed, wire-based laser metal deposition (LMD-W) processes are superior to powder-based processes due to the smaller reactive surface. Nowadays, three main challenges exist when titanium grade 5 (Ti6Al4V) is processed by additive manufacturing (AM): First of all, the high affinity to oxygen combined with the increased brittleness of the material in case of a contamination with already low amounts of oxygen has to be faced. Second, the material is prone to distortion induced by thermal stress during the manufacturing process. Finally, the material has a complex bimodal microstructure, which has to be adjusted properly to generate optimal strength. The following publication will present how these technical challenges are faced. The heat input into the workpiece and thereby the area that has to be covered with shielding gas is minimized. This is done by minimizing the laser spot size as well as adjusting the travel speed. Thereby a local shielding of the process was realized. With this optimized process, it was possible to generate several specimens for metallurgical analysis.

Experimental Investigation of Temperature Distribution during Wire-Based Laser Metal Deposition of the Al-Mg Alloy 5087

Wire-based laser metal deposition enables to manufacture large-scale components with deposition rates significant higher compared to powder-based laser additive manufacturing techniques, which are currently working with deposition rates of only a few hundred gram per hour. However, the wire-based approach requires a significant amount of laser power in the range of several kilowatts instead of only a few hundred watts for powder-based processes. This excessive heat input during laser metal deposition can lead to process instabilities such as a non-uniform material deposition and to a limited processability, respectively. Although, numerous possibilities to monitor temperature evolution during processing exist, there is still a lack of knowledge regarding the relationship between temperature and geometric shape of the deposited structure. Due to changing cooling conditions with increasing distance to the substrate material, producing a wall-like structure results in varying heights of the individual tracks. This presents challenges for the deposition of high wall-like structures and limits the use of constant process parameters. In the present study, the temperature evolution during laser metal deposition of AA5087 using constant process parameters is investigated and a scheme for process parameter adaptions in order to reduce residual stress induced componential distortions is suggested.

Process development for wire-based laser metal deposition of 5087 aluminium alloy by using fibre laser

In recent decades, laser metal deposition, as a part of additive manufacturing, developed into a promising methodology in industrial fields. In recent years, there has been an increased interest in the processability of lightweight high-strength structural materials, such as aluminium alloys. However, in terms of wire-based laser metal deposition, there is still a lack of knowledge with regard to the processability of aluminium alloys. In this research, the process development for wire-based laser metal deposition of a 5087 aluminium alloy (AlMg4.5 MnZr) has been conducted. It is observed that pre-heating is beneficial in terms of porosity and distortion reduction. Within optimized parameter ranges, it is possible to control the geometric shape, dilution, and aspect ratios of the deposited layers in a systematic way. Accordingly, defect-free layers with tailored geometrical features can be processed and adapted to specific process requirements.

Microstructure and microhardness of wire-based laser metal deposited AA5087 using an Ytterbium fibre laser

Wire-based additive manufacturing has been increasingly investigated in recent years. Although it is possible nowadays to manufacture structures that are free from inner defects such as porosity and cracks using wire and arc additive manufacturing, there is still a lack of knowledge regarding wire-based laser metal deposition of aluminium and its alloys. In order to be able to produce locally tailored part properties, it is necessary to understand the process parameter to material property relationships. Using laser energy sources, it becomes possible to analyse in detail the heat input and to observe occurring microstructural evolutions. This work includes a microstructural and mechanical characterization of an AA5087 wall structure. Detailed analyses of the chemical composition, texture, and microhardness of the structure have been performed. The microstructure contains different grain orientations as well as grain shapes and sizes along the structure, resulting in locally different material properties. The results have been analysed and discussed in reference to fundamental theories such as the Hall–Petch and Orowan mechanisms.