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<p>In this study, thin-walled parts of ER 4043 Al-5Si alloys were deposited using the cold metal transfer (CMT)-wire arc additive manufacturing (WAAM) process. The effects of variation of process parameters of wire feed speed (WFS), interlayer time interval (ITI), and travel speed (TS) on the microstructure and mechanical properties of thin-walled parts were investigated. The results showed that the microstructures of the thin-walled parts were composed of the α-Al phase and Al-Si eutectic phase. The samples deposited by WAAM consisted mainly of a large number of columnar grains and a few equiaxial grains. As WFS increased, heat input increased and reduced the temperature gradient; the average grain size of thin-walled parts increased significantly from 90&#xa0;μm to 135&#xa0;μm. The maximum texture intensity of the thin-walled parts is also increased. The ultimate tensile strength (UTS) of the samples decreased from 134 to 101&#xa0;MPa. As ITI increased, the average grain size of thin-walled parts decreased from 122 to 85&#xa0;μm due to higher subcooling and temperature gradient. This resulted in an increase in UTS from 104 to 130&#xa0;MPa. Although the increased TS enhances the solidification rate, the average grain size of the thin-walled parts only decreases from 145 to 129&#xa0;μm. The UTS of thin-walled parts was increased from 123 to 146&#xa0;MPa. The tensile fractures of the samples were plastic fractures; therefore, the samples maintained high elongation (EL). In addition, the anisotropy in the mechanical properties results from differences in grain size, directional growth and inhomogeneous grain structure, eutectic microstructure, and texture.</p>

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Influence of process parameters on microstructure and mechanical properties of ER 4043 Al-5Si alloys fabricated by wire arc additive manufacturing

  • 期刊论文

  • 发表日期：

    2025年5月14日

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  • Yongxing Li,
  • Dongyu Liu,
  • Yansong Huang,
  • Zeyu Yang,
  • Xin Shang

摘要

In this study, thin-walled parts of ER 4043 Al-5Si alloys were deposited using the cold metal transfer (CMT)-wire arc additive manufacturing (WAAM) process. The effects of variation of process parameters of wire feed speed (WFS), interlayer time interval (ITI), and travel speed (TS) on the microstructure and mechanical properties of thin-walled parts were investigated. The results showed that the microstructures of the thin-walled parts were composed of the α-Al phase and Al-Si eutectic phase. The samples deposited by WAAM consisted mainly of a large number of columnar grains and a few equiaxial grains. As WFS increased, heat input increased and reduced the temperature gradient; the average grain size of thin-walled parts increased significantly from 90 μm to 135 μm. The maximum texture intensity of the thin-walled parts is also increased. The ultimate tensile strength (UTS) of the samples decreased from 134 to 101 MPa. As ITI increased, the average grain size of thin-walled parts decreased from 122 to 85 μm due to higher subcooling and temperature gradient. This resulted in an increase in UTS from 104 to 130 MPa. Although the increased TS enhances the solidification rate, the average grain size of the thin-walled parts only decreases from 145 to 129 μm. The UTS of thin-walled parts was increased from 123 to 146 MPa. The tensile fractures of the samples were plastic fractures; therefore, the samples maintained high elongation (EL). In addition, the anisotropy in the mechanical properties results from differences in grain size, directional growth and inhomogeneous grain structure, eutectic microstructure, and texture.