Effect of Travel Speed on the Properties of 5087 Aluminum Alloy Walls Produced by Wire and Arc Additive Manufacturing

An innovative Wire and Arc Additive Manufacturing combines the well-studied process of arc welding with direct energy deposition. Effect of travel speed 5.0 and 7.5 mm/s on the microstructure and mechanical properties of 5087 aluminum alloy was investigated. Five thousand eighty-three aluminum alloy was used as a substrate material and 5087 aluminum alloy was utilized as a filler material for the walls fabrication. The presence of pores reducing the strength of the overlay weld metal was detected on both overlay welds. The lower welding speed (5 mm/s) resulted in the smaller amount of porosity in comparison to higher welding speed (7.5 mm/s). Average pore area of wall No. 1 was 0.66% and wall No. 2 was 1.13%. It was found that higher welding speed affected the wall width and overlay weld bead geometry. Increase in welding speed led to a narrowing of wall width from 10.23 to 8.44 mm. The microstructure of weld metal matrix consisted of a α-Al substitution solid solution. The tensile strength of parallel to welding direction removed samples exceeded the tensile strength of perpendicular removed samples. It is a result of the cohesion of the layers in the overlay welding direction compared to the non-uniformity of the layers in the perpendicular direction. Furthermore, the tensile strength was higher in the case of travel speed of 5 mm/s in comparison to that of 7.5 mm/s.