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<p>To address porosity, anisotropy, and coarse grains in wire arc additively manufactured aluminum alloys, rare earth Ce was introduced into 2319 alloy via dual-wire arc additive manufacturing, using an ER2319 main wire and a Ce-cored auxiliary wire. Under the optimized parameters of a main wire current of 165&#xa0;A, voltage of 19.4&#xa0;V, and auxiliary wire feed speed of 0.5&#xa0;m/min, smoothly formed straight walls exhibited surface fluctuations within 0.439&#xa0;mm and arc deflection below 2°. The droplet transfer mode shifted from globular to contact and then to fine droplets with increasing current. Microstructural characterization revealed the formation of spherical Al<sub>11</sub>Ce<sub>3</sub> phases (~ 100&#xa0;nm) in the melt pool. The average lattice misfit between Al<sub>11</sub>Ce<sub>3</sub> and the α-Al matrix was 9.30%, confirming its effectiveness as a heterogeneous nucleation site. At 0.23 wt.% Ce, grain refinement was most pronounced, reducing the grain sizes in the middle and top regions to 63.51&#xa0;μm and 65.04&#xa0;μm, respectively—an overall reduction of 14.81%, while promoting equiaxed grain formation. Grain boundary strengthening provided the highest contribution to the enhanced strength. The optimized process successfully fabricated high multi-rib thin-walled telemetry cabin, demonstrating its potential for high-quality and cost-effective production of large-scale aluminum alloy components.</p> Graphical Abstract <p></p>

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Optimization and microstructural-property regulation of Ce-alloyed 2319 aluminum alloy by dual-wire arc additive manufacturing

  • 期刊论文

  • 发表日期：

    2026年1月9日

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  • Huadong Zhang,
  • Tianying He,
  • Yu Shengfu,
  • Meng Xiaohao,
  • Yu Wuxin

摘要

To address porosity, anisotropy, and coarse grains in wire arc additively manufactured aluminum alloys, rare earth Ce was introduced into 2319 alloy via dual-wire arc additive manufacturing, using an ER2319 main wire and a Ce-cored auxiliary wire. Under the optimized parameters of a main wire current of 165 A, voltage of 19.4 V, and auxiliary wire feed speed of 0.5 m/min, smoothly formed straight walls exhibited surface fluctuations within 0.439 mm and arc deflection below 2°. The droplet transfer mode shifted from globular to contact and then to fine droplets with increasing current. Microstructural characterization revealed the formation of spherical Al11Ce3 phases (~ 100 nm) in the melt pool. The average lattice misfit between Al11Ce3 and the α-Al matrix was 9.30%, confirming its effectiveness as a heterogeneous nucleation site. At 0.23 wt.% Ce, grain refinement was most pronounced, reducing the grain sizes in the middle and top regions to 63.51 μm and 65.04 μm, respectively—an overall reduction of 14.81%, while promoting equiaxed grain formation. Grain boundary strengthening provided the highest contribution to the enhanced strength. The optimized process successfully fabricated high multi-rib thin-walled telemetry cabin, demonstrating its potential for high-quality and cost-effective production of large-scale aluminum alloy components.

Graphical Abstract