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<p>Wire arc additive manufacturing demonstrates significant potential for the high-efficiency fabrication large-scale metallic component. However, parameter optimization for high-quality parts, particularly for the hard-to-weld aluminum alloys like 2319, remains a challenge. This study investigated the effects of arc current (I) on the process stability and formation mechanisms of WAAMed 2319 aluminum alloy thin wall. The results showed that increasing the I from 140 to 160 A not only enhanced the effective width coefficient of deposited thin wall from 70.14 to 75.45%, but also improved the forming accuracy by 25% through a reduction in machining allowance from 3.44 to 2.58&#xa0;mm. However, as the I further increased to 180 A, the porosity significantly increased from 0.51 to 2.06%. While the increased arc current improved droplet transfer by inducing a globular-to-spray transition and refined the re-melted zone microstructure through columnar-to-equiaxed grain transformation, it concurrently caused grain coarsening in the arc-melted zone. At the optimized I of 160 A, peak mechanical properties were achieved with an ultimate tensile strength of 282.18&#xa0;MPa and elongation of 10.31%, corresponding to respective improvements of 5.23% and 25.58%. Through a balanced control of droplet dynamics, thermal regulation and defect suppression, the optimal arc current significantly improves the forming quality of depositions.</p>

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Process Stability and Formation Mechanism of Aluminum Alloy Thin Wall Fabricated by Wire Arc Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2025年10月16日

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  • Xiaohan Guo,
  • Yunfei Meng,
  • Qianxi Yu,
  • Jianeng Xu,
  • Xu Wu,
  • Hui Chen

摘要

Wire arc additive manufacturing demonstrates significant potential for the high-efficiency fabrication large-scale metallic component. However, parameter optimization for high-quality parts, particularly for the hard-to-weld aluminum alloys like 2319, remains a challenge. This study investigated the effects of arc current (I) on the process stability and formation mechanisms of WAAMed 2319 aluminum alloy thin wall. The results showed that increasing the I from 140 to 160 A not only enhanced the effective width coefficient of deposited thin wall from 70.14 to 75.45%, but also improved the forming accuracy by 25% through a reduction in machining allowance from 3.44 to 2.58 mm. However, as the I further increased to 180 A, the porosity significantly increased from 0.51 to 2.06%. While the increased arc current improved droplet transfer by inducing a globular-to-spray transition and refined the re-melted zone microstructure through columnar-to-equiaxed grain transformation, it concurrently caused grain coarsening in the arc-melted zone. At the optimized I of 160 A, peak mechanical properties were achieved with an ultimate tensile strength of 282.18 MPa and elongation of 10.31%, corresponding to respective improvements of 5.23% and 25.58%. Through a balanced control of droplet dynamics, thermal regulation and defect suppression, the optimal arc current significantly improves the forming quality of depositions.