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<p>Thin-wall structures of Ti-6Al-4&#xa0;V alloy were fabricated using a fast-frequency single-pulse wire arc additive manufacturing (FFSP-WAAM) process, and the effects of key waveform parameters on arc behavior, microstructure, and mechanical properties were systematically investigated. An increase in pulse current amplitude or frequency effectively constricts the arc and concentrates the heat input, thereby facilitating the escape of gas bubbles from the molten pool and reducing porosity. The intensified arc force, together with an ultrasonic-like vibration effect, promotes vigorous stirring of the molten pool, thereby disrupting the growth of β dendrites and refining the grains. Enhanced molten pool convection accelerates the cooling rate, thereby resulting in finer martensitic and basket-weave microstructures and promoting the precipitation of nanoscale secondary α phases. Moreover, the reduced variant selection of α phases at prior β grain boundaries helps mitigate the material’s anisotropy. At a fast-frequency current of 180&#xa0;A and​ a base current of 70&#xa0;A, the deposited alloy shows an average microhardness of 338.6 Hv, a tensile strength of 924.3&#xa0;MPa, and an elongation of 8.9%, which represent respective increases of 18.1 Hv, 84.1&#xa0;MPa, and 29.0% compared with those at fast-frequency current 30&#xa0;A and a base current of 145&#xa0;A. Overall, this study provides a robust theoretical basis for the application of FFSP-WAAM in fabricating titanium alloy aerospace components.</p>

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Influence of process parameters in fast-frequency single-pulse wire arc additive manufacturing on the microstructure and mechanical properties of Ti-6Al-4 V alloy

  • 期刊论文

  • 发表日期：

    2026年3月9日

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  • Yingwei Kuang,
  • Haipeng Liao,
  • Haibing Xiao,
  • Peng Chi,
  • Qin Zhang,
  • Jianliang Hu,
  • Zhenmin Wang

摘要

Thin-wall structures of Ti-6Al-4 V alloy were fabricated using a fast-frequency single-pulse wire arc additive manufacturing (FFSP-WAAM) process, and the effects of key waveform parameters on arc behavior, microstructure, and mechanical properties were systematically investigated. An increase in pulse current amplitude or frequency effectively constricts the arc and concentrates the heat input, thereby facilitating the escape of gas bubbles from the molten pool and reducing porosity. The intensified arc force, together with an ultrasonic-like vibration effect, promotes vigorous stirring of the molten pool, thereby disrupting the growth of β dendrites and refining the grains. Enhanced molten pool convection accelerates the cooling rate, thereby resulting in finer martensitic and basket-weave microstructures and promoting the precipitation of nanoscale secondary α phases. Moreover, the reduced variant selection of α phases at prior β grain boundaries helps mitigate the material’s anisotropy. At a fast-frequency current of 180 A and​ a base current of 70 A, the deposited alloy shows an average microhardness of 338.6 Hv, a tensile strength of 924.3 MPa, and an elongation of 8.9%, which represent respective increases of 18.1 Hv, 84.1 MPa, and 29.0% compared with those at fast-frequency current 30 A and a base current of 145 A. Overall, this study provides a robust theoretical basis for the application of FFSP-WAAM in fabricating titanium alloy aerospace components.