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<p>The wire arc additive manufacturing (WAAM) method for fabricating Al-magnesium alloy components, such as engine blocks and chassis, exhibits considerable potential. Nonetheless, challenges related to anisotropy in structure and performance, along with stability during high–low-temperature cycles, impede its wider adoption. This study aimed to enhance the mechanical properties and uniformity of the microstructure of deposited samples through the application of ultrasonic assistance (UA) technology. Concurrently, it sought to explore the potential connections between the microstructure, properties, and residual stresses of WAAM and UA-WAAM 5A83 Al alloy samples following cycles of high–low temperatures. Results showed that UA effectively inhibits the formation of columnar grains and refines the grain structure, with the average grain diameter decreasing from 104.4 to 74.58&#xa0;μm. This grain refinement, coupled with enhanced solid solution strengthening, leads to an improved mechanical performance of the deposits. Following high–low-temperature cycling, the microstructure and secondary phases of both WAAM and UA-WAAM 5A83 samples remained stable; however, the samples of UA-WAAM exhibit a more uniform hardness distribution.</p>

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Strengthening Mechanisms and Structural Homogenization in Ultrasound-Assisted Wire Arc-Directed Energy Deposition 5A83 Al Alloys

  • 期刊论文

  • 发表日期：

    2025年9月15日

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  • Wei Luo,
  • Peng Xu,
  • Hua Du,
  • Ming Zhang,
  • Jianhua Chen

摘要

The wire arc additive manufacturing (WAAM) method for fabricating Al-magnesium alloy components, such as engine blocks and chassis, exhibits considerable potential. Nonetheless, challenges related to anisotropy in structure and performance, along with stability during high–low-temperature cycles, impede its wider adoption. This study aimed to enhance the mechanical properties and uniformity of the microstructure of deposited samples through the application of ultrasonic assistance (UA) technology. Concurrently, it sought to explore the potential connections between the microstructure, properties, and residual stresses of WAAM and UA-WAAM 5A83 Al alloy samples following cycles of high–low temperatures. Results showed that UA effectively inhibits the formation of columnar grains and refines the grain structure, with the average grain diameter decreasing from 104.4 to 74.58 μm. This grain refinement, coupled with enhanced solid solution strengthening, leads to an improved mechanical performance of the deposits. Following high–low-temperature cycling, the microstructure and secondary phases of both WAAM and UA-WAAM 5A83 samples remained stable; however, the samples of UA-WAAM exhibit a more uniform hardness distribution.