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<p>Ceramic phase modification is an effective method to improve the performance of wire arc additive manufacturing (WAAM) aluminum alloy components. In this paper, a preparation method of ceramic aluminum alloy flux-cored wire was developed. An advanced apparatus was developed for the preparation of flux-cored wires. The preparation system comprises three integral units: a wire forming module, a drawing module, and a coiling module. The wire forming module features a configuration of three forming rollers and three closed dies, while the drawing and reduction module incorporates 12 sets of wire drawing dies with varying diameters, with each stage maintaining a controlled compression ratio of 20%. The fluidization properties of the core powder mixture were systematically examined, revealing that optimal powder flow characteristics were achieved when the constituent particles were sized as follows: aluminum particles at 300&#xa0;μm, copper particles at 250&#xa0;μm, and silicon particles at 200&#xa0;μm. The pre-heat treatment parameters for the aluminum strip substrate were optimized, with the process conditions established as follows: heating temperature of 230&#xa0;°C, soaking duration of 120&#xa0;min, and air cooling as the cooling method. Through a sequential series of 12 drawing and reduction operations, a 1.2&#xa0;mm diameter Al-Cu-NiO aluminum alloy flux-cored wire was successfully fabricated. During the WAAM process employing the developed Al-Cu-NiO flux-cored wire, the process exhibited stable arc combustion, consistent droplet transfer, and minimal spatter. The developed flux-cored wire was successfully utilized to fabricate the aircraft skin, demonstrating high formability and suitability for such applications.</p>

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The preparation method and application of aluminum alloy flux-cored wire for wire arc additive manufacturing

  • 期刊论文

  • 发表日期：

    2025年10月30日

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  • Bo Zheng,
  • Shengfu Yu,
  • Zhengyu Yu,
  • Lun Tang

摘要

Ceramic phase modification is an effective method to improve the performance of wire arc additive manufacturing (WAAM) aluminum alloy components. In this paper, a preparation method of ceramic aluminum alloy flux-cored wire was developed. An advanced apparatus was developed for the preparation of flux-cored wires. The preparation system comprises three integral units: a wire forming module, a drawing module, and a coiling module. The wire forming module features a configuration of three forming rollers and three closed dies, while the drawing and reduction module incorporates 12 sets of wire drawing dies with varying diameters, with each stage maintaining a controlled compression ratio of 20%. The fluidization properties of the core powder mixture were systematically examined, revealing that optimal powder flow characteristics were achieved when the constituent particles were sized as follows: aluminum particles at 300 μm, copper particles at 250 μm, and silicon particles at 200 μm. The pre-heat treatment parameters for the aluminum strip substrate were optimized, with the process conditions established as follows: heating temperature of 230 °C, soaking duration of 120 min, and air cooling as the cooling method. Through a sequential series of 12 drawing and reduction operations, a 1.2 mm diameter Al-Cu-NiO aluminum alloy flux-cored wire was successfully fabricated. During the WAAM process employing the developed Al-Cu-NiO flux-cored wire, the process exhibited stable arc combustion, consistent droplet transfer, and minimal spatter. The developed flux-cored wire was successfully utilized to fabricate the aircraft skin, demonstrating high formability and suitability for such applications.