<p>This study investigates the synergistic effects of deposition sequence and arc oscillation on the interface and properties of wire arc additively manufactured 2319/5356 dissimilar aluminum alloys. Addressing challenges such as poor bonding and inconsistent performance, a Box-Behnken design with response surface methodology was employed to optimize arc oscillation parameters (frequency, amplitude, and torch angle) targeting hardness and porosity. Results indicate that the 2319-on-5356 deposition sequence yields superior performance, exhibiting excellent surface flatness, sufficient interfacial element diffusion, and the formation of strengthening phases like Al<sub>2</sub>Cu, Al<sub>2</sub>CuMg, and Al<sub>3</sub>Mg<sub>2</sub>. Under the optimal parameters (amplitude 6.19 mm, frequency 4.0 Hz, angle 82.2°), experimental validation confirmed that the component achieved a low actual porosity of 0.81% and an average hardness of 89.3 HV<sub>0.2</sub>, strongly verifying the accuracy of the established Box-Behnken model. Compared to the process without oscillation, the optimized strategy refined the average grain size to 21.23 μm and increased tensile strength by 29.11% to 216.46 MPa. Additionally, corrosion uniformity was significantly improved. These findings demonstrate that coordinated control of deposition sequence and arc oscillation effectively mitigates defects and enhances the mechanical properties of heterogeneous aluminum components.</p>

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Interface and Properties of Additively Manufactured 2319/5356 Dissimilar Alloys: Deposition Sequence-Arc Oscillation Synergy

  • Yi Zhang,
  • Jian Gou,
  • Ju Gao,
  • Jingshuai Zhu,
  • Wenqiang Kou

摘要

This study investigates the synergistic effects of deposition sequence and arc oscillation on the interface and properties of wire arc additively manufactured 2319/5356 dissimilar aluminum alloys. Addressing challenges such as poor bonding and inconsistent performance, a Box-Behnken design with response surface methodology was employed to optimize arc oscillation parameters (frequency, amplitude, and torch angle) targeting hardness and porosity. Results indicate that the 2319-on-5356 deposition sequence yields superior performance, exhibiting excellent surface flatness, sufficient interfacial element diffusion, and the formation of strengthening phases like Al2Cu, Al2CuMg, and Al3Mg2. Under the optimal parameters (amplitude 6.19 mm, frequency 4.0 Hz, angle 82.2°), experimental validation confirmed that the component achieved a low actual porosity of 0.81% and an average hardness of 89.3 HV0.2, strongly verifying the accuracy of the established Box-Behnken model. Compared to the process without oscillation, the optimized strategy refined the average grain size to 21.23 μm and increased tensile strength by 29.11% to 216.46 MPa. Additionally, corrosion uniformity was significantly improved. These findings demonstrate that coordinated control of deposition sequence and arc oscillation effectively mitigates defects and enhances the mechanical properties of heterogeneous aluminum components.