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<p>Aluminum 1050 is widely valued for its excellent thermal and electrical conductivity, corrosion resistance, and relevance in industrial applications. However, its use in additive manufacturing, particularly for structural applications, remains limited. This study explores the potential of fabricating Aluminum 1050 components using Wire Arc Additive Manufacturing (WAAM), a method known for its low cost and high deposition rates. Experiments were conducted using a vertical machining centre (VMC) integrated with a Fronius welding torch and 100% argon shielding gas, with Aluminum 6063 as the substrate. The effects of welding current, voltage, travel speed, standoff distance, and wire feed rate on defect formation, such as porosity, lack of fusion, cracking, and surface roughness, were systematically examined. Results show that the vertical surface exhibited 38.7% higher peak roughness (Rz) despite lower average roughness (Ra and Rq), indicating directional surface variation due to layer deposition and cooling. Nozzle deformation and material buildup were also evaluated under extended operation. The findings contribute to optimizing WAAM process parameters for improved structural performance of Aluminum 1050 components. Optimal values, such as 95 A current, 300&#xa0;mm/min travel speed, and 8&#xa0;mm standoff distance, significantly reduced defects. Porosity distribution in the deposited components was measured at 0.985%, indicating the effectiveness of the selected process parameters.</p> Graphical abstract <p></p>

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Investigation of defect formation and nozzle behaviour in WAAM of aluminium alloy under different process parameters

  • 期刊论文

  • 发表日期：

    2025年6月18日

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  • Sujata Sahoo,
  • Somashekara M Adinarayanappa,
  • Anbukkarasi Rajendran

摘要

Aluminum 1050 is widely valued for its excellent thermal and electrical conductivity, corrosion resistance, and relevance in industrial applications. However, its use in additive manufacturing, particularly for structural applications, remains limited. This study explores the potential of fabricating Aluminum 1050 components using Wire Arc Additive Manufacturing (WAAM), a method known for its low cost and high deposition rates. Experiments were conducted using a vertical machining centre (VMC) integrated with a Fronius welding torch and 100% argon shielding gas, with Aluminum 6063 as the substrate. The effects of welding current, voltage, travel speed, standoff distance, and wire feed rate on defect formation, such as porosity, lack of fusion, cracking, and surface roughness, were systematically examined. Results show that the vertical surface exhibited 38.7% higher peak roughness (Rz) despite lower average roughness (Ra and Rq), indicating directional surface variation due to layer deposition and cooling. Nozzle deformation and material buildup were also evaluated under extended operation. The findings contribute to optimizing WAAM process parameters for improved structural performance of Aluminum 1050 components. Optimal values, such as 95 A current, 300 mm/min travel speed, and 8 mm standoff distance, significantly reduced defects. Porosity distribution in the deposited components was measured at 0.985%, indicating the effectiveness of the selected process parameters.

Graphical abstract