Comparison of Forming Quality, Microstructure and Properties of Four Types of Aluminum Alloy Components Fabricated by Wire and Arc Additive Manufacturing

WANG Jin; YU Huasen; YU Zuying; SUN Jianxin; ZHANG Jun; ZHANG Mengqi; ZHAO Hongli

doi:10.7512/j.issn.1001-2303.2024.03.06

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Comparison of Forming Quality, Microstructure and Properties of Four Types of Aluminum Alloy Components Fabricated by Wire and Arc Additive Manufacturing
Vol. 54, Issue 3, Pages: 36-42(2024)
Published： 25 March 2024 ，
DOI： 10.7512/j.issn.1001-2303.2024.03.06

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王晋，虞华森，余祖英，等.四种铝合金焊丝电弧增材制造构件的成形质量和组织性能对比研究［J］.电焊机，2024，54（3）：36-42.

WANG Jin, YU Huasen, YU Zuying, et al.Comparison of Forming Quality, Microstructure and Properties of Four Types of Aluminum Alloy Components Fabricated by Wire and Arc Additive Manufacturing[J].Electric Welding Machine, 2024, 54(3): 36-42.
王晋，虞华森，余祖英，等.四种铝合金焊丝电弧增材制造构件的成形质量和组织性能对比研究［J］.电焊机，2024，54（3）：36-42. DOI： 10.7512/j.issn.1001-2303.2024.03.06.

WANG Jin, YU Huasen, YU Zuying, et al.Comparison of Forming Quality, Microstructure and Properties of Four Types of Aluminum Alloy Components Fabricated by Wire and Arc Additive Manufacturing[J].Electric Welding Machine, 2024, 54(3): 36-42. DOI： 10.7512/j.issn.1001-2303.2024.03.06.

摘要

为了比较不同铝合金焊丝对电弧增材制造过程的适应性，选用ER1070、ER2A12、ER4043和ER5356四种典型铝合金焊丝，采用脉冲MIG电弧熔丝增材制造方法，在同等热输入条件下电弧增材制造直壁构件。通过热分析、表面波纹度计算、微观组织观察、硬度和力学性能测试，研究了四种焊丝在电弧增材成形、组织结构及力学性能方面的差异。结果表明，ER5356焊丝在电弧沉积过程中产生的飞溅最少，相应的直壁构件Al5356成形质量最好，表面波纹度值最小。四种铝合金直壁构件的微观组织差异明显，其中Al1070组织最粗大，孔隙缺陷最多；Al2A12组织为细小的等轴晶，Al4043的组织为发达Al-Si共晶，Al5356的基体最致密。力学性能测试显示，四种铝合金直壁构件在X向的抗拉强度高于Z向，Al1070和Al4043在

向和

向上的延伸率差异比Al2A12和Al5356的大。Al1070的平均硬度和抗拉强度最低，但延伸率最高；Al2A12的平均硬度和抗拉强度最高，但延伸率不足10%，组织内存在的微裂纹限制了其力学性能的进一步提升；Al5356的平均抗拉强度略低于Al2A12，平均延伸率超过20%，表现出较好的综合力学性能。综上所述，ER5356焊丝更适合电弧增材制造铝合金构件，Al5356构件具有最佳的综合性能。

Abstract

To compare the adaptability of different aluminum alloy wires to the arc additive manufacturing process

four typical aluminum alloy wires (ER1070

ER2A12

ER4043

and ER5356) were selected. Using the pulse MIG arc wire additive manufacturing method

thin-walled components were fabricated under the same heat input conditions. The differences in arc additive forming

microstructure

and mechanical properties of the four wires were studied through thermal analysis

surface waviness calculation

microstructure observation

hardness

and mechanical property testing. The results showed that ER5356 wire produced the least spatter during arc deposition

and the corresponding Al5356 thin-walled component had the best forming quality and the smallest surface waviness value. The microstructure of the four aluminum alloy thin-walled components was significantly different

with Al1070 having the coarsest structure and the most porosity defects; Al2A12 having fine equiaxed grains; Al4043 having developed Al-Si eutectic structure; and Al5356 having the densest matrix. Mechanical property testing showed that the tensile strength of the four aluminum alloy thin-walled components was higher in the X direction than in the Z direction

and the elongation difference between the X and Z directions of Al1070 and Al4043 was greater than that of Al2A12 and Al5356. Al1070 had the lowest average hardness and tensile strength

but the highest elongation; Al2A12 had the highest average hardness and tensile strength

but the elongation was less than 10%

and the microcracks in the structure limited the further improvement of its mechanical properties; Al5356 had slightly lower average tensile strength than Al2A12

with an average elongation of over 20%

showing good comprehensive mechanical properties. In summary

ER5356 wire is more suitable for arc additive manufacturing of aluminum alloy components

and Al5356 components have the best comprehensive performance.

关键词

电弧增材制造铝合金成形质量微观组织力学性能

Keywords

wire and arc additive manufacturingaluminum alloyforming qualitymicrostructuremechanical property

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