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Understanding the microstructural evolution and fatigue behavior of aluminum 2319 fabricated by wire arc additive manufacturing

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Abstract

Aluminum alloys have received substantial interest for the fabrication of complex and large size components for the aerospace industry via additive manufacturing processes. This work explores the fatigue performance of aluminum alloy 2319 fabricated by wire-based Directed Energy Deposition (DED) with Cold Metal Transfer (CMT) process, i.e., wire arc additive manufacturing (WAAM) technology. The as-deposited 2319 wall microstructure was composed by both columnar dendrites and equiaxed grains along the build direction (BD). Also, fine and coarse θ and θ′ precipitates were noticed in the WAAM printed 2319 wall due to repeated thermal cycles while fine precipitates were observed in wrought alloy. The microhardness measurements revealed a gradual decrease from the bottom to the top layers and varied between 65 and 86 HV. Tensile properties (yield strength, ultimate tensile strength, and elongation) measured in the horizontal and vertical directions were 99 ± 4 MPa, 268 ± 11 MPa 14.8 ± 1.5% and 96 ± 3 MPa, 257 ± 9 MPa, and 15.6 ± 2%, respectively. The WAAM 2319 fabricated in this work retained 72% of the strength of their AA2219-T62 wrought counterparts, which can be attributed to the large columnar grains that developed during the additive manufacturing process. The fatigue strength of WAAM 2319 specimen was 67 MPa, corresponding to 65% of the fatigue strength of AA2219-T62. Fracture surface analysis revealed the presence of small and large dimples, secondary micro-cracks, broken intermetallics, and inclusions. This work will provide novel insights and guidance for manufacturing near-net shape aluminum alloys by wire-based DED with improved tensile and fatigue properties.

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The data that support the findings of this study are available on request from the corresponding author.

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Acknowledgements

This research was financially supported by the Ministry of Trade, Industry, and Energy (MOTIE), Korea, under the “Innovative Digital Manufacturing Platform” (reference number P00223311) supervised by the Korea Institute for Advancement of Technology (KIAT). This work was also supported by the National Research Foundation of Korea (NRF) grant funded by the Korean government (2022R1A4A3031263). Finally, JPO acknowledges funding by national funds from FCT—Fundação para a Ciência e a Tecnologia, I.P., in the scope of the projects LA/P/0037/2020, UIDP/50025/2020 and UIDB/50025/2020 of the Associate Laboratory Institute of Nanostructures, Nanomodelling and Nanofabrication–i3N.

Funding

Ministry of Trade, Industry and Energy, P00223311, National Research Foundation of Korea, 2022R1A4A3031263, Faculdade de Ciências e Tecnologia, Universidade Nova de Lisboa, LA/P/0037/2020,UIDP/50025/2020, UIDB/50025/2020.

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Authors and Affiliations

  1. Department of Mechanical Engineering, BK21 FOUR ERICA-ACE Center, Hanyang University, 55, Hanyangdaehak-ro, Sangnok-gu, Ansan-si, Gyeonggi-do, 15588, Republic of Korea

    A. Rajesh Kannan & Jonghun Yoon

  2. Department of Mechanical Engineering, National Institute of Technology, Tiruchirappalli, Tamil Nadu, 620015, India

    R. Pramod, K. Sanjeevi Prakash & N. Siva Shanmugam

  3. AIDICOME Inc., 55, Hanyangdaehak-ro, Ansan, Gyeonggi-do, 15588, Republic of Korea

    Jonghun Yoon

  4. Department of Mechanical and Industrial Engineering, UNIDEMI, NOVA School of Science and Technology, Universidade NOVA de Lisboa, 2829-516, Caparica, Portugal

    J. P. Oliveira

  5. Department of Materials Science, School of Science and Technology, CENIMAT|i3N, NOVA University Lisbon, Caparica, Portugal

    J. P. Oliveira

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  1. A. Rajesh Kannan
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Kannan, A.R., Pramod, R., Prakash, K.S. et al. Understanding the microstructural evolution and fatigue behavior of aluminum 2319 fabricated by wire arc additive manufacturing. Archiv.Civ.Mech.Eng 24, 110 (2024). https://doi.org/10.1007/s43452-024-00925-6

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