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Abstract <p>This study investigates the local corrosion resistance mechanisms of 2024 aluminum alloy (AA2024) fabricated through cold metal transfer with pulse wire arc additive manufacturing (CMT + P WAAM) at different arc travel speeds (ATSs). A quantitative relationship is established between the process parameters, corrosion resistance, and microstructure. Electrochemical corrosion behavior is evaluated using performance testing and various characterization techniques (XRD, EDS, TEM, and EBSD), with results indicating that pitting corrosion is the primary form of degradation. This corrosion is primarily caused by aluminum matrix dissolution, chloride-induced corrosion, and magnesium dealloying. Arc travel speed significantly influences corrosion resistance, with a transition from pitting corrosion dominance at lower ATS to uniform corrosion at higher ATS. Additionally, arc travel speed affects grain size, deformation texture, and secondary phase precipitation, suggesting that the interaction between process parameters and grain boundary stability governs corrosion sensitivity. This study proposes a novel approach to enhancing the corrosion resistance of aluminum alloy additive parts.</p> Graphical Abstract <p></p>

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Effect of Arc Travel Speed on Corrosion Resistance of AA2024 by Cold Metal Transfer with Pulsed Wire Arc Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2025年11月3日

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  • Xuecheng Lu,
  • Shuai Zhuo,
  • Zhiqiang Zhang,
  • Junpei Yan,
  • Yang Zhao,
  • Pan Gong,
  • Yueze Dong,
  • Ziyan Zhang,
  • Tiangang Zhang,
  • Hongli Liu

摘要

Abstract

This study investigates the local corrosion resistance mechanisms of 2024 aluminum alloy (AA2024) fabricated through cold metal transfer with pulse wire arc additive manufacturing (CMT + P WAAM) at different arc travel speeds (ATSs). A quantitative relationship is established between the process parameters, corrosion resistance, and microstructure. Electrochemical corrosion behavior is evaluated using performance testing and various characterization techniques (XRD, EDS, TEM, and EBSD), with results indicating that pitting corrosion is the primary form of degradation. This corrosion is primarily caused by aluminum matrix dissolution, chloride-induced corrosion, and magnesium dealloying. Arc travel speed significantly influences corrosion resistance, with a transition from pitting corrosion dominance at lower ATS to uniform corrosion at higher ATS. Additionally, arc travel speed affects grain size, deformation texture, and secondary phase precipitation, suggesting that the interaction between process parameters and grain boundary stability governs corrosion sensitivity. This study proposes a novel approach to enhancing the corrosion resistance of aluminum alloy additive parts.

Graphical Abstract