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<p>Due to the limitations of traditional manufacturing methods and single-arc wire arc additive manufacturing (WAAM) in processing 2319 aluminum alloy, particularly regarding coarse grain structure, porosity defects, and insufficient mechanical properties. This study proposed integrating friction stir processing (FSP) with WAAM technology, systematically examines the microstructural evolution induced by multi-pass friction stir processing, and characterizes the resultant structural behavior in multi-layer fabricated components. The results demonstrated significant grain refinement through multi-pass processing, achieving an average grain size of 2.1&#xa0;µm. Notably, the substrate maintains ultrafine-grained microstructure (1.7&#xa0;µm) despite thermal cycling from subsequent deposition layers. Moreover, the mechanical properties of the composite samples were good, and the yield strength, ultimate tensile strength and elongation were 164.3&#xa0;MPa, 231.8&#xa0;MPa and 7.8%. Compared to the WAAM, improvements of 104%, 8%, and 69% were achieved. The sample achieved the microhardness of 94.5 HV<sub>0.2.</sub></p>

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Microstructure Evolution and Grain Refinement in 2319 Aluminum Alloy by Hybrid Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2026年5月16日

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  • Yuhang Gou,
  • Xianhao Jiang,
  • Yanhua Guo,
  • Guoqing Dai,
  • Zhonggang Sun

摘要

Due to the limitations of traditional manufacturing methods and single-arc wire arc additive manufacturing (WAAM) in processing 2319 aluminum alloy, particularly regarding coarse grain structure, porosity defects, and insufficient mechanical properties. This study proposed integrating friction stir processing (FSP) with WAAM technology, systematically examines the microstructural evolution induced by multi-pass friction stir processing, and characterizes the resultant structural behavior in multi-layer fabricated components. The results demonstrated significant grain refinement through multi-pass processing, achieving an average grain size of 2.1 µm. Notably, the substrate maintains ultrafine-grained microstructure (1.7 µm) despite thermal cycling from subsequent deposition layers. Moreover, the mechanical properties of the composite samples were good, and the yield strength, ultimate tensile strength and elongation were 164.3 MPa, 231.8 MPa and 7.8%. Compared to the WAAM, improvements of 104%, 8%, and 69% were achieved. The sample achieved the microhardness of 94.5 HV0.2.