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<p>This study presents a comparative investigation of ER4043 and ER4047 aluminum alloys fabricated using TIG-based wire arc additive manufacturing (WAAM), focusing on the relationships between processing parameters, microstructure, mechanical performance, and corrosion behavior. Response surface methodology (RSM) was employed to optimize key process variables, enabling the deposition of defect-free walls with stable bead geometry and strong interlayer bonding. Microstructural analysis revealed that ER4047, owing to its higher silicon content, developed a finer Al-Si eutectic structure and refined grains compared to ER4043. Consequently, ER4047 exhibited superior mechanical properties, achieving an ultimate tensile strength of 160&#xa0;MPa, hardness of 48 HV, and elongation of 13%, representing an improvement of approximately 8-12% over ER4043 under identical processing conditions. Microhardness measurements along the build height showed a gradual variation influenced by thermal accumulation during deposition. Fractography examination indicated predominantly ductile fracture behavior in ER4047, whereas ER4043 showed mixed ductile–brittle characteristics. Salt spray corrosion testing demonstrated significantly enhanced corrosion resistance of ER4047, attributed to the formation of a dense and stable Al-Si-O passive layer that effectively suppressed pitting. Overall, the results identify ER4047 as a more suitable filler alloy for corrosion-sensitive and load-bearing TIG–WAAM applications, while confirming the effectiveness of RSM-based optimization in improving the performance of WAAM-fabricated aluminum alloys.</p>

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Comparative Evaluation of Microstructural, Mechanical and Tribology Properties of ER4043 and ER4047 Aluminum Alloys Fabricated by TIG-based Wire Arc Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2026年2月25日

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  • A. Muthu Kumaran,
  • S. Jeyakumar,
  • Senthil Maharaj Kennedy,
  • T. Nithyanandhan

摘要

This study presents a comparative investigation of ER4043 and ER4047 aluminum alloys fabricated using TIG-based wire arc additive manufacturing (WAAM), focusing on the relationships between processing parameters, microstructure, mechanical performance, and corrosion behavior. Response surface methodology (RSM) was employed to optimize key process variables, enabling the deposition of defect-free walls with stable bead geometry and strong interlayer bonding. Microstructural analysis revealed that ER4047, owing to its higher silicon content, developed a finer Al-Si eutectic structure and refined grains compared to ER4043. Consequently, ER4047 exhibited superior mechanical properties, achieving an ultimate tensile strength of 160 MPa, hardness of 48 HV, and elongation of 13%, representing an improvement of approximately 8-12% over ER4043 under identical processing conditions. Microhardness measurements along the build height showed a gradual variation influenced by thermal accumulation during deposition. Fractography examination indicated predominantly ductile fracture behavior in ER4047, whereas ER4043 showed mixed ductile–brittle characteristics. Salt spray corrosion testing demonstrated significantly enhanced corrosion resistance of ER4047, attributed to the formation of a dense and stable Al-Si-O passive layer that effectively suppressed pitting. Overall, the results identify ER4047 as a more suitable filler alloy for corrosion-sensitive and load-bearing TIG–WAAM applications, while confirming the effectiveness of RSM-based optimization in improving the performance of WAAM-fabricated aluminum alloys.