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<p>Wire arc additive manufacturing (WAAM) provides advantages such as complex geometries and reduced waste, but its mechanical and tribological properties differ from those of traditionally manufactured parts. While aluminum alloy parts fabricated via WAAM have broad applications in industries like aerospace, automotive, and marine, they usually encounter challenges like high friction and wear. Therefore, studying the tribological behavior is essential to ensure the durability and performance of WAAM walls of aluminum alloys in such demanding environments. In this current study, the CMT-based WAAM technique was used to fabricate three bimetallic walls with ER4043 and ER5356 filler wires, employing three heat input combinations: low (223.8&#xa0;J/mm and 162&#xa0;J/mm), medium (236.8&#xa0;J/mm and 175.2&#xa0;J/mm), and high (251.7&#xa0;J/mm and 186.7&#xa0;J/mm).The tribological performance of each wall was assessed under varying loads (20&#xa0;N, 30&#xa0;N, and 40&#xa0;N), followed by a detailed analysis of the walls exhibiting the lowest wear rates. The results revealed that the wall fabricated with the low heat input exhibited the minimum wear rate (0.0019 mm<sup>3</sup>/m) under a 20&#xa0;N load and the lowest coefficient of friction of 0.25 under a 40&#xa0;N load, specifically in the ER5356 layer, where adhesive and delamination wear mechanisms were observed. Optical and field emission scanning electron microscopy, along with electron backscatter diffraction imaging of the wall with the minimum wear rate, showed equiaxed coarse grains in the ER4043 layer, finer grains in the ER5356 layer, and fine equiaxed grains at the interface layer. The ER5356 layer exhibited the highest hardness, being 21.86% and 6.77% greater than the interface and ER4043 layers, respectively. Additionally, the energy absorbed during impact was 25.76&#xa0;J, and fractography analysis confirmed a ductile fracture mode characterized by dimples and voids.</p>

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Influence of Heat Input Variations on Tribological Performance of Bimetallic Aluminum Alloy Walls Fabricated via Cold Metal Transfer-Based Wire Arc Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2025年3月6日

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  • Soni Kesarwani,
  • Narayana Yuvaraj,
  • Mahendra Singh Niranjan

摘要

Wire arc additive manufacturing (WAAM) provides advantages such as complex geometries and reduced waste, but its mechanical and tribological properties differ from those of traditionally manufactured parts. While aluminum alloy parts fabricated via WAAM have broad applications in industries like aerospace, automotive, and marine, they usually encounter challenges like high friction and wear. Therefore, studying the tribological behavior is essential to ensure the durability and performance of WAAM walls of aluminum alloys in such demanding environments. In this current study, the CMT-based WAAM technique was used to fabricate three bimetallic walls with ER4043 and ER5356 filler wires, employing three heat input combinations: low (223.8 J/mm and 162 J/mm), medium (236.8 J/mm and 175.2 J/mm), and high (251.7 J/mm and 186.7 J/mm).The tribological performance of each wall was assessed under varying loads (20 N, 30 N, and 40 N), followed by a detailed analysis of the walls exhibiting the lowest wear rates. The results revealed that the wall fabricated with the low heat input exhibited the minimum wear rate (0.0019 mm3/m) under a 20 N load and the lowest coefficient of friction of 0.25 under a 40 N load, specifically in the ER5356 layer, where adhesive and delamination wear mechanisms were observed. Optical and field emission scanning electron microscopy, along with electron backscatter diffraction imaging of the wall with the minimum wear rate, showed equiaxed coarse grains in the ER4043 layer, finer grains in the ER5356 layer, and fine equiaxed grains at the interface layer. The ER5356 layer exhibited the highest hardness, being 21.86% and 6.77% greater than the interface and ER4043 layers, respectively. Additionally, the energy absorbed during impact was 25.76 J, and fractography analysis confirmed a ductile fracture mode characterized by dimples and voids.