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<p>Additive manufacturing (AM) of aluminium alloys enables complex geometries, reduced waste, and customization but poses challenges when welded with conventionally manufactured parts, primarily due to porosity issues. This study optimizes gas metal arc welding (GMAW), focusing on cold metal transfer (CMT), to join these components. Key factors include filler metal selection, shielding gas, and laser cleaning for surface preparation. Powder bed fusion-laser beam (PBF-LB) parts showed higher porosity than directed energy deposition-arc (DED-Arc) parts due to powder oxidation. ER 5356 (AlMg5Cr) filler metal and pure argon shielding gas improved weld quality, while laser cleaning reduced oxide layers and porosity. The findings highlight parameter optimization’s importance in integrating AM and conventional methods for high-performance applications.</p>

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Optimization of GMAW welding for additively manufactured aluminium alloys: insights into filler metal, shielding gas, and laser cleaning

  • 期刊论文

  • 发表日期：

    2025年5月5日

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  • Rafael Nunes,
  • Koen Faes,
  • Wim Verlinde,
  • Wim De Waele,
  • Matthieu Lezaack,
  • Aude Simar

摘要

Additive manufacturing (AM) of aluminium alloys enables complex geometries, reduced waste, and customization but poses challenges when welded with conventionally manufactured parts, primarily due to porosity issues. This study optimizes gas metal arc welding (GMAW), focusing on cold metal transfer (CMT), to join these components. Key factors include filler metal selection, shielding gas, and laser cleaning for surface preparation. Powder bed fusion-laser beam (PBF-LB) parts showed higher porosity than directed energy deposition-arc (DED-Arc) parts due to powder oxidation. ER 5356 (AlMg5Cr) filler metal and pure argon shielding gas improved weld quality, while laser cleaning reduced oxide layers and porosity. The findings highlight parameter optimization’s importance in integrating AM and conventional methods for high-performance applications.