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The wire-arc directed energy deposition (WA-DED) process is currently the most time-efficient and cost-effective method for producing large, nearly net-shaped metal parts. By predefining a path and using an arc as the heat source, it melts the filler wire and deposits it along the predefined path. The application of Al-Zn-Mg-Cu alloys is of particular interest due to their lightweight and high specific strength, especially in the aerospace industry. However, during the WA-DED process of aluminum alloys, rapid cooling rates can lead to severe element segregation, resulting in brittle eutectic formations along grain boundaries, which significantly affect the material’s corrosion resistance. Subsequent heat treatment processes can effectively reduce the presence of eutectic structures, thereby improving corrosion resistance to some extent. Additionally, WA-DED-based Al-Zn-Mg-Cu alloys are prone to the formation of porosities, which can have a detrimental impact on mechanical properties, especially fatigue performance. This chapter explores the corrosion resistance properties of WA-DED applied Al-Zn-Mg-Cu alloys under different heat treatment conditions. Furthermore, the fatigue performance is also investigated.

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High-Cycle Fatigue Fracture and Corrosion Behavior of an Aerospace Alloy Manufactured with the Wire-Arc Directed Energy Deposition Technology

  • 章节

  • 发表日期：

    2025年

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  • Xinpeng Guo,
  • Huijun Li,
  • Zengxi Pan,
  • Bosheng Dong,
  • Zhijun Qiu,
  • Chengxun Zhang,
  • Hu Huang

摘要

The wire-arc directed energy deposition (WA-DED) process is currently the most time-efficient and cost-effective method for producing large, nearly net-shaped metal parts. By predefining a path and using an arc as the heat source, it melts the filler wire and deposits it along the predefined path. The application of Al-Zn-Mg-Cu alloys is of particular interest due to their lightweight and high specific strength, especially in the aerospace industry. However, during the WA-DED process of aluminum alloys, rapid cooling rates can lead to severe element segregation, resulting in brittle eutectic formations along grain boundaries, which significantly affect the material’s corrosion resistance. Subsequent heat treatment processes can effectively reduce the presence of eutectic structures, thereby improving corrosion resistance to some extent. Additionally, WA-DED-based Al-Zn-Mg-Cu alloys are prone to the formation of porosities, which can have a detrimental impact on mechanical properties, especially fatigue performance. This chapter explores the corrosion resistance properties of WA-DED applied Al-Zn-Mg-Cu alloys under different heat treatment conditions. Furthermore, the fatigue performance is also investigated.