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<p>The microstructure of wire arc additively manufactured (WAAMed) Al-2219 was found to be substantially different from those produced through conventional processing methods. A heterogeneous microstructure, consisting of fine equiaxed grains and coarse columnar grain bands with alternating distribution, was formed in the as-built state. This unique microstructure can be tailored by adjusting process parameters, offering opportunities to enhance mechanical properties without the need for complex processes or changes in chemical composition. The superior mechanical properties and excellent strength–ductility synergy (ultimate tensile strength of 310 ± 15 MPa, yield strength of 110 ± 5 MPa, and uniform elongation of 18% ± 2) compared to other additive manufacturing techniques and conventional methods were discussed, relying on the specific microstructure characteristics of the fabricated wall. Detailed analysis of strain-hardening behavior and load–unload–reloading (LUR) tests revealed that hetero deformation induced (HDI) strengthening contributes approximately 42% to the overall flow stress. In addition, this research explores the effect of solutionizing and T6 heat treatment on the microstructural changes and corresponding mechanical properties of the WAAM-processed parts. The heterogeneous as-built microstructure was found to be thermally stable, and the combined effect of the heterogeneous microstructure and T6 heat treatment caused substantial improvement in yield strength (340 ± 8 MPa) and ultimate tensile strength (510 ± 12 MPa), surpassing those properties found in the wrought state.</p>

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Heterogeneous microstructure enables strength–ductility synergy in 2219 aluminium alloy fabricated by wire arc additive manufacturing (WAAM)

  • 期刊论文

  • 发表日期：

    2025年2月6日

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  • Niyusha Akhavan Malayeri,
  • Abbas Zarei‐Hanzaki,
  • Ali Moshiri,
  • Alireza Abbasi,
  • Hamid Reza Abedi

摘要

The microstructure of wire arc additively manufactured (WAAMed) Al-2219 was found to be substantially different from those produced through conventional processing methods. A heterogeneous microstructure, consisting of fine equiaxed grains and coarse columnar grain bands with alternating distribution, was formed in the as-built state. This unique microstructure can be tailored by adjusting process parameters, offering opportunities to enhance mechanical properties without the need for complex processes or changes in chemical composition. The superior mechanical properties and excellent strength–ductility synergy (ultimate tensile strength of 310 ± 15 MPa, yield strength of 110 ± 5 MPa, and uniform elongation of 18% ± 2) compared to other additive manufacturing techniques and conventional methods were discussed, relying on the specific microstructure characteristics of the fabricated wall. Detailed analysis of strain-hardening behavior and load–unload–reloading (LUR) tests revealed that hetero deformation induced (HDI) strengthening contributes approximately 42% to the overall flow stress. In addition, this research explores the effect of solutionizing and T6 heat treatment on the microstructural changes and corresponding mechanical properties of the WAAM-processed parts. The heterogeneous as-built microstructure was found to be thermally stable, and the combined effect of the heterogeneous microstructure and T6 heat treatment caused substantial improvement in yield strength (340 ± 8 MPa) and ultimate tensile strength (510 ± 12 MPa), surpassing those properties found in the wrought state.