Influence of arc mode on the microstructure and mechanical properties of 5356 aluminum alloy fabricated by wire arc additive manufacturing

In this paper, two arc modes of gas shielded metal arc welding (GMAW), a new pulsed mode (microMIG) and a non-pulsed mode (microMIG-CC), were used to melt ER5356 aluminum alloy wire for thin-wall fabrication. The influence of both arc modes on the melt-drop transition pattern, thin-wall properties, porosity, microstructure and mechanical properties was investigated at the same heat input. The microMIG mode adds SKS-based current time based on conventional pulsed GMAW for short-circuiting the transition, which leads to a faster spread of melt pool temperature. The rapid cooling of the melt pool contributed to the increase of grain nucleation rate and inhibited grain growth, resulting in smaller grain size in the microMIG mode specimens. In addition, the low porosity of microMIG specimens is attributed to the high voltage of the micro-MIG mode resulting in an unfocused heat source, which leads to a shallow penetration depth of the specimens and a reduced hydrogen escape distance. Compared with the microMIG-CC mode, the microMIG mode specimens have smaller grain size and lower porosity, therefore higher tensile strength is obtained. The isotropic property of thin walls is due to the existence of equiaxed grains and the random distribution of grain orientation. However, the aggrega-tion of dislocations and the increase of precipitates make microMIG-CC have higher hardness. Overall, the mechanical properties of the thin wall specimens of WAAM 5356 aluminum alloy are higher than those of the as-cast specimens.(c) 2022 The Author(s). Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).