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Wire arc additive manufacturing enables the cost-efficient production of medium to large-scale metal parts with precise shaping; however, working with aluminium presents challenges, especially in addressing porosity. This study investigates the effect of varying argon gas flow rates on porosity in ER4043-AlSi5 (wt%) components fabricated through the GTAW-based WAAM process. The results indicated that, as we increase the shielding gas flow rate, the number of pores increases in fabricated aluminium alloy parts due to an increase in cooling rate, which prevents the trapped gases from escaping. Based on observations, at 2 l/min gas flow rate, the number of pores is minimal but more significant compared to parts fabricated at 6, 10, and 14 l/min. The distribution of pore area increases as the gas flow rate rises from 2 to 10 l/min, but then decreases significantly when the gas flow rate reaches 14 l/min.

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Porosity Control in 4043 Aluminium Alloy Fabricated Through Wire Arc Additive Manufacturing Process

  • 会议论文

  • 发表日期：

    2025年

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  • Chanchal Chauhan,
  • Kumar Ujjwal,
  • Mukul Anand,
  • Alok Kumar Das

摘要

Wire arc additive manufacturing enables the cost-efficient production of medium to large-scale metal parts with precise shaping; however, working with aluminium presents challenges, especially in addressing porosity. This study investigates the effect of varying argon gas flow rates on porosity in ER4043-AlSi5 (wt%) components fabricated through the GTAW-based WAAM process. The results indicated that, as we increase the shielding gas flow rate, the number of pores increases in fabricated aluminium alloy parts due to an increase in cooling rate, which prevents the trapped gases from escaping. Based on observations, at 2 l/min gas flow rate, the number of pores is minimal but more significant compared to parts fabricated at 6, 10, and 14 l/min. The distribution of pore area increases as the gas flow rate rises from 2 to 10 l/min, but then decreases significantly when the gas flow rate reaches 14 l/min.