Enhancing mechanical properties and defects elimination in 2024 aluminum alloy through interlayer friction stir processing in wire arc additive manufacturing

In this study, a hybrid wire arc additive manufacturing (WAAM) and interlayer friction stir processing (IFSP) approach was utilized to enhance the quality of 2024 aluminum alloy components. The defects characteristic, microstructure evolution, and mechanical properties of the fabricated components and after T6 heat treatment were analyzed systematically. Our analysis reveals that IFSP can break and dissolve the eutectic phases, significantly reduce porosity defects and refine the grain size of the as-deposited materials, thus improving the overall mechanical properties. Notably, compared to the WAAM as-deposited component, the yield strength (YS) and ultimate tensile strength (UTS) in the top-layer stir zone (SZ) of IFSP component increased from 154 +/- 3 to 267 +/- 2 MPa, and from 258 +/- 12 to 360 +/- 3 MPa, respectively. However, in the middle-layer SZ, S-phase precipitation and coarsening induced by thermal cycling during additive manufacturing slightly reduced the tensile properties. Post-T6 heat treatment led to uniformly distributed properties in the IFSP component along both horizontal and vertical directions, with the YS, UTS, and elongation (EL) averaging 353 +/- 9 MPa, 470 +/- 4 MPa, and 10.5 +/- 1.6%, closely matching those of wrought counterparts. The significant improvements in mechanical properties are primarily attributed to the elimination of porosity and precipitation of fine needle-like Sphase. This research not only demonstrates the potential of IFSP in enhancing the mechanical properties of WAAM-fabricated 2024 aluminum alloy but also offers a promising technique for producing high-quality components suitable for high-performance aerospace applications.