Research Status and Development Trend of Wire Arc Additive Manufacturing Technology for Aluminum Alloys
Abstract
:1. Introduction
2. WAAM Digital Control System and the Parameters Monitoring
2.1. WAAM Digital Control System
2.1.1. CAD Model Processing and Slicing Algorithm
2.1.2. Path Planning
2.2. Processing Parameters
2.2.1. Current
2.2.2. Wire Feeding Speed (WFS)
2.2.3. Travel Speed (TS)
2.2.4. Shielding Gas
2.2.5. Auxiliary Additive Manufacturing
3. WAAM Process Regulation
3.1. Heat Input
3.2. Alloy Composition
3.3. Heat Treatment
4. Mechanical Properties of the WAAM Deposition
5. Application
6. Future Prospects
- (1)
- Combining the numerical simulation with WAAM experiments. Numerical simulation technology is necessary to be used in simulating the entire process of metal materials moving, softening, melting, flowing, solidifying, and accumulating under the action of heat sources. Then, the effects of process parameters on the morphology, microstructure, and stress of the deposited parts should be deeply analyzed. Finally, the defects and microstructural evolution principles in the forming process should also be explained from the perspectives of the temperature field, flow field, and stress field in the WAAM process. Furthermore, the internal relationship among path planning, processing parameters, and alloy composition are explored, so as to guide parameter regulation and optimization in the actual experimental process.
- (2)
- Developing special wire materials for aluminum alloy arc additive manufacturing. 6XXX and 7XXX series aluminum alloys are attractive materials applied in the aerospace industry. However, due to the difficulty in manufacturing and processing special wire materials for high-strength aluminum alloys, there are still few research reports on WAAM for high-strength aluminum alloys. In addition, in the face of the characteristics of different regional performance requirements during the service process of complex components, it is urgent to develop and select different-composition metal wire materials to improve the overall performance and service life of structural components.
- (3)
- To realize the additive manufacturing technology of aluminum alloy suitable for complex service environments. It is urgent to develop in situ repair and rapid manufacturing technology for damaged parts in extreme environments, such as ocean carriers, underwater, underground, and space, so as to effectively solve the problem of difficulty in replacing the damaged parts.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Aluminum Alloy | Heat Source | Parameter | Processing Method | Average Grain Size (μm) | Tensile Strength (MPa) | Yield Strength (MPa) | Hardness (HV) | Forming Quality | Ref. |
---|---|---|---|---|---|---|---|---|---|
Al-Zn-Mg-Cu | CMT | WFS: 6.5 m/min TS: 0.54 m/min | T6 Heat treatment | 6 | 618 (Ultimate) | 542 | / | Composed of fine equiaxed grains, eutectic structures were precipitated. | [74] |
Al-Zn-Mg | MIG | TS: 0.2–0.35 m/min Current: 97–112 A | / | / | 299 (Ultimate) | 188 | 112 | The weld bead smoother, with a few pores on weld bead. | [75] |
4043 | TIG | WFS: 1.0 m/min TS: 0.25 m/min | Laser-arc hybrid additive manufacturing | / | 151.91 | 69.71 | 49.97 | Finer grains, the microstructure morphology in different zones is different. | [76] |
2219 + TiC particles | TIG | WFS: 2.0 m/min TS: 0.2 m/min | / | / | 384 | / | / | The surface roughness of the specimens increased, eliminated the slender columnar grains, and refined the Grains. | [68] |
6061 | CMT | WFS: 6.0 m/min TS: 0.36 m/min | Friction stir processing | 5 | 257 (Ultimate) | 142 | 99.71 | Significant microstructure refinement and porosity reduction. | [77] |
2319 + 5087 | GTAW | WFS: 2.4 m/min (2319) 1.05 m/min (5087) TS: 0.3 m/min | T4 Heat treatment + T6 Heat treatment | / | 458 (T4, Ultimate) 470 (T6, Ultimate) | 310 (T4) 374 (T6) | 138 (T4) 146 (T6) | Obvious dendrite morphology disappeared, layer-distributing characteristics of the phases became obvious. | [78] |
7075 + TiC particles | GTAW | WFS: 3.0 m/min TS: 0.24 m/min | T6 Heat treatment | / | Significant improvement | Significant improvement | 193 | Finer grains, the adiabatic shear band is first generated with an increase in the strain rate. | [66] |
7075 + TiC particles | GTAW | WFS: 3.0 m/min TS: 0.24 m/min | / | 15.2 | 435 | 310 | / | Uneven microstructural features and grain boundary segregation were eliminated | [69] |
5087 | CMT | WFS: 6.0 m/min TS: 0.6 m/min | Interlayer rolling | / | 344 (Ultimate) | 240 | 107.2 | Primary coarse grain structures were found to become greatly refined with an evident rolling texture after deformation. | [79] |
2319 | CMT | WFS: 4.0 m/min TS: 0.48 m/min | Low- frequency vibration | 16 | 266.1 (Ultimate) | 120.6 | / | Refines the grain size, and reduces the texture density. | [80] |
5356 + 7A48 | CMT | WFS: 10.1 m/min TS: 0.6 m/min | Hot rolling | 51.6 | 392.3 | 280.2 | 72 (5356) 160 (7A48) | Heterogeneous plate with lamella structure and without any noticeable crack defects. | [81] |
2319 | CMT | WFS: 5.6 m/min TS: 1.8 m/min | Friction stir processing | 4.98 | 289.6 (Ultimate) | 162.9 | 88 | Ultrafine grains, equiaxed grains, columnar grains, gradient microstructure. | [82] |
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Dai, P.; Li, A.; Zhang, J.; Chen, R.; Luo, X.; Wen, L.; Wang, C.; Lv, X. Research Status and Development Trend of Wire Arc Additive Manufacturing Technology for Aluminum Alloys. Coatings 2024, 14, 1094. https://doi.org/10.3390/coatings14091094
Dai P, Li A, Zhang J, Chen R, Luo X, Wen L, Wang C, Lv X. Research Status and Development Trend of Wire Arc Additive Manufacturing Technology for Aluminum Alloys. Coatings. 2024; 14(9):1094. https://doi.org/10.3390/coatings14091094
Chicago/Turabian StyleDai, Pan, Ao Li, Jianxun Zhang, Runjie Chen, Xian Luo, Lei Wen, Chen Wang, and Xianghong Lv. 2024. "Research Status and Development Trend of Wire Arc Additive Manufacturing Technology for Aluminum Alloys" Coatings 14, no. 9: 1094. https://doi.org/10.3390/coatings14091094