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<p>Wire Arc&#xa0;Additive manufacturing&#xa0;(WAAM) is one of the most progressive technique used to fabricate components by depositing material in layer-by-layer sequence using inert gas welding. Aluminum–silicon alloys are commonly used in aircraft and automotive industries due to their excellent mechanical and metallurgical properties. In this work, interface metallurgical characteristics and mechanical properties of ER4043 aluminium silicon alloy deposited using WAAM process were investigated. The experimental results showed that the hardness of the deposited layers decreased with increase in the specific energy of welding. In multi-layer deposition, an increase in the hardness was observed in the previous deposited layers and at the interface zone due to reformation of large columnar grains into small grains and precipitation of more eutectic silicon content. The Scanning Electron Microscopy (SEM) images indicated that the formation of pores and delamination at the interface zone due to variation in the cooling rate during solidification and also due to formation of oxides at the interface zone. The increase in the specific energy causes formation of more oxides on the weld deposit surface due to high weld temperature results from high heat input. In Electron Back Scatter Diffraction (EBSD) analysis, the variation in crystal orientation, grain size, misorientation of grains and texture orientation were observed at the interface zone. The mechanical properties such as tensile, compressive and impact strength were observed at low level and requires post treatment process for improvement.</p>

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Interface Metallurgical Characteristics and Mechanical Properties of ER4043 Aluminum Alloys in Wire Arc Additive Manufacturing Process

  • 期刊论文

  • 发表日期：

    2025年8月20日

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  • G. Ravi Kiran Sastry,
  • K. Venkateswarlu,
  • CH R. Vikram Kumar

摘要

Wire Arc Additive manufacturing (WAAM) is one of the most progressive technique used to fabricate components by depositing material in layer-by-layer sequence using inert gas welding. Aluminum–silicon alloys are commonly used in aircraft and automotive industries due to their excellent mechanical and metallurgical properties. In this work, interface metallurgical characteristics and mechanical properties of ER4043 aluminium silicon alloy deposited using WAAM process were investigated. The experimental results showed that the hardness of the deposited layers decreased with increase in the specific energy of welding. In multi-layer deposition, an increase in the hardness was observed in the previous deposited layers and at the interface zone due to reformation of large columnar grains into small grains and precipitation of more eutectic silicon content. The Scanning Electron Microscopy (SEM) images indicated that the formation of pores and delamination at the interface zone due to variation in the cooling rate during solidification and also due to formation of oxides at the interface zone. The increase in the specific energy causes formation of more oxides on the weld deposit surface due to high weld temperature results from high heat input. In Electron Back Scatter Diffraction (EBSD) analysis, the variation in crystal orientation, grain size, misorientation of grains and texture orientation were observed at the interface zone. The mechanical properties such as tensile, compressive and impact strength were observed at low level and requires post treatment process for improvement.