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<p>Arc-wire directed energy deposition (AW-DED) in Al-5&#xa0;Mg alloys has emerged as a promising technique for fabricating large-scale metallic components. A high temperature gradient and a rapid cooling rate promote the formation of columnar grains. The preferred equiaxed structure is not achievable in the conventional AW-DED process with a GMAW power source due to high arc energy and steep thermal gradients during deposition. In this study, using the short-circuiting metal transfer mode to achieve a near-equiaxed structure, the process parameters for AW-DED of Al-5&#xa0;Mg single beads were optimised by correlating the mean current and travel speed. A 20-layer thin wall was manufactured using the optimised parameters. Low mean current and low travel speed during short-circuit metal transfer resulted in a low heat input and a shallow temperature gradient, leading to a near-equiaxed microstructure. Mechanical property evaluation was performed to determine the isotropic characteristics of the AW-DED parts produced.</p>

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Optimisation of Arc-Wire Directed Energy Deposition Parameters for Al-5356 Alloy to Promote Equiaxed Grain Formation

  • 期刊论文

  • 发表日期：

    2026年6月16日

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  • Sherin Thampi,
  • Hariharan Krishnaswamy,
  • Murugaiyan Amirthalingam

摘要

Arc-wire directed energy deposition (AW-DED) in Al-5 Mg alloys has emerged as a promising technique for fabricating large-scale metallic components. A high temperature gradient and a rapid cooling rate promote the formation of columnar grains. The preferred equiaxed structure is not achievable in the conventional AW-DED process with a GMAW power source due to high arc energy and steep thermal gradients during deposition. In this study, using the short-circuiting metal transfer mode to achieve a near-equiaxed structure, the process parameters for AW-DED of Al-5 Mg single beads were optimised by correlating the mean current and travel speed. A 20-layer thin wall was manufactured using the optimised parameters. Low mean current and low travel speed during short-circuit metal transfer resulted in a low heat input and a shallow temperature gradient, leading to a near-equiaxed microstructure. Mechanical property evaluation was performed to determine the isotropic characteristics of the AW-DED parts produced.