Skip to main content

Advertisement

SpringerLink
Log in

Comparative Study on Wire-Arc Additive Manufacturing and Conventional Casting of Al–Si Alloys: Porosity, Microstructure and Mechanical Property

  • Published:
Acta Metallurgica Sinica (English Letters) Aims and scope

Abstract

Here, we compare the porosity, microstructure and mechanical property of 4047 Al–Si alloys prepared by wire-arc additive manufacturing (WAAM) and conventional casting. X-ray microscopy reveals that WAAM causes a higher volume fraction of gas pores in comparison with conventional casting. Effective refinements of α-Al dendrites, eutectic Si particles and Fe-rich intermetallic compounds are achieved by WAAM, resulting from its rapid solidification process. Both ultimate tensile strength (UTS, up to 205.6 MPa) and yield stress (YS, up to 98.0 MPa) are improved by WAAM at the expense of elongation after fracture. The mechanical property anisotropy between scanning direction and build direction is minimal for alloys via WAAM. Additional microstructure refinement and strength enhancement are enabled by increasing the travel speed of welding torch from 300 to 420 mm/min.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9

Similar content being viewed by others

References

  1. M. Köhler, S. Fiebig, J. Hensel, K. Dilger, Metals 9, 608 (2019)

    Article  Google Scholar 

  2. Y. Zhou, X. Lin, N. Kang, W. Huang, J. Wang, Z. Wang, J. Mater. Sci. Technol. 37, 143 (2020)

    Article  Google Scholar 

  3. R. Fu, S. Tang, J. Lu, Y. Cui, Z. Li, H. Zhang, T. Xu, Z. Chen, C. Liu, Mater. Des. 199, 109370 (2021)

    Article  CAS  Google Scholar 

  4. J.L. Gu, J.L. Ding, B.Q. Cong, J. Bai, H.M. Gu, S.W. Williams, Y.C. Zhai, Adv. Mater. Res. 1081, 210 (2014)

    Article  Google Scholar 

  5. H. Li, J. Zou, J. Yao, H. Peng, J. Alloys Compd. 727, 531 (2017)

    Article  CAS  Google Scholar 

  6. B. Cong, Z. Qi, B. Qi, H. Sun, G. Zhao, J. Ding, Appl. Sci. 7, 275 (2017)

    Article  Google Scholar 

  7. D. Zhang, G. Wang, A. Wu, J. Shan, Y. Zhao, T. Zhao, D. Meng, J. Song, Z. Zhang, Acta Metall. Sin. Engl. Lett. 32, 684 (2019)

    Article  CAS  Google Scholar 

  8. D. Wang, J. Lu, S. Tang, L. Yu, H. Fan, L. Ji, C. Liu, Materials 11, 1344 (2018)

    Article  Google Scholar 

  9. T. Lu, C. Liu, Z. Li, Q. Wu, J. Wang, T. Xu, J. Liu, H. Wang, S. Ma, J. Alloys Compd. 817, 153334 (2020)

    Article  CAS  Google Scholar 

  10. Z. Li, N. Limodin, A. Tandjaoui, P. Quaegebeur, J. Witz, D. Balloy, Mater. Sci. Eng. A 794, 139920 (2020)

    Article  CAS  Google Scholar 

  11. B. Cong, J. Ding, S. Williams, Int. J. Adv. Manuf. Technol. 76, 1593 (2015)

    Article  Google Scholar 

  12. O. Panchenko, D. Kurushkin, I. Mushnikov, A. Khismatullin, A. Popovich, Mater. Des. 195, 109040 (2020)

    Article  CAS  Google Scholar 

  13. A. Elrefaey, N.G. Ross, Acta Metall. Sin. -Engl. Lett. 28, 715 (2015)

    Article  CAS  Google Scholar 

  14. Q. Miao, D. Wu, D. Chai, Y. Zhan, G. Bi, F. Niu, G. Ma, Mater. Des. 186, 108205 (2020)

    Article  CAS  Google Scholar 

  15. B. Dong, X. Cai, S. Lin, X. Li, C. Fan, C. Yang, H. Sun, Addit. Manuf. 36, 101447 (2020)

    CAS  Google Scholar 

  16. Z. Qi, B. Cong, B. Qi, H. Sun, G. Zhao, J. Ding, J. Mater. Process. Technol. 255, 347 (2018)

    Article  CAS  Google Scholar 

  17. C. Su, X. Chen, C. Gao, Y. Wang, Appl. Surf. Sci. 486, 431 (2019)

    Article  CAS  Google Scholar 

  18. Q. Yang, C. Xia, Y. Deng, X. Li, H. Wang, Materials 12, 432 (2019)

    Article  Google Scholar 

  19. A.S. Haselhuhn, M.W. Buhr, B. Wijnen, P.G. Sanders, J.M. Pearce, Mater. Sci. Eng. A 673, 511 (2016)

    Article  CAS  Google Scholar 

  20. T.A. Mai, A.C. Spowage, Mater. Sci. Eng. A 374, 224 (2004)

    Article  Google Scholar 

  21. J.L. Murray, A.J. McAlister, Bull. Alloy Phase Diagrams 5, 74 (1984)

    Article  CAS  Google Scholar 

  22. Y. Zhao, Y. Jia, S. Chen, J. Shi, F. Li, Addit. Manuf. 32, 100935 (2020)

    Google Scholar 

  23. Y. Guo, L. Jia, S. Sun, B. Kong, J. Liu, H. Zhang, Mater. Des. 109, 37 (2016)

    Article  CAS  Google Scholar 

  24. A.J. Shahani, X. Xiao, P.W. Voorhees, Nat. Commun. 7, 12953 (2016)

    Article  CAS  Google Scholar 

  25. J. Wang, S. He, B. Sun, Q. Guo, M. Nishio, J. Mater. Process. Technol. 141, 29 (2003)

    Article  CAS  Google Scholar 

  26. X.P. Li, X.J. Wang, M. Saunders, A. Suvorova, L.C. Zhang, Y.J. Liu, M.H. Fang, Z.H. Huang, T.B. Sercombe, Acta Mater. 95, 74 (2015)

    Article  CAS  Google Scholar 

  27. L. Huang, X. Chen, S. Konovalov, A.N. Siddiquee, G. Lu, X. Pan, Metals 11, 267 (2021)

    Article  CAS  Google Scholar 

  28. T. Mukherjee, V. Manvatkar, A. De, T. DebRoy, Scr. Mater. 127, 79 (2017)

    Article  CAS  Google Scholar 

  29. S. Najafi, A.R. Eivani, M. Samaee, H.R. Jafarian, J. Zhou, Mater. Charact. 136, 60 (2018)

    Article  CAS  Google Scholar 

  30. W. Xu, L.P. Dávila, Mater. Sci. Eng. A 710, 413 (2018)

    Article  CAS  Google Scholar 

  31. E. Ghassemali, M. Riestra, T. Bogdanoff, B.S. Kumar, S. Seifeddine, Procedia Eng. 207, 19 (2017)

    Article  CAS  Google Scholar 

  32. H. Lien, J. Mazumder, J. Wang, A. Misra, Mater. Res. Lett. 8, 291 (2020)

    Article  CAS  Google Scholar 

  33. L. Kuchariková, M. Mazur, E. Tillová, M. Chalupová, D. Závodská, A. Vaško, Eng. Failure Anal. 105, 688 (2019)

    Article  Google Scholar 

  34. H. Li, B. Lin, R. Xu, K. Liu, H. Xiao, Y. Zhao, Mater. Sci. Technol. 36, 307 (2020)

    Article  CAS  Google Scholar 

  35. T. Ma, J. Ge, Y. Chen, T. Jin, Y. Lei, Mater. Lett. 237, 266 (2019)

    Article  CAS  Google Scholar 

  36. A.P. Boeira, I.L. Ferreira, A. Garcia, Mater. Des. 30, 2090 (2009)

    Article  CAS  Google Scholar 

  37. J. Gu, J. Ding, S.W. Williams, H. Gu, P. Ma, Y. Zhai, J. Mater. Process. Technol. 230, 26 (2016)

    Article  CAS  Google Scholar 

  38. E.M. Ryan, T.J. Sabin, J.F. Watts, M.J. Whiting, J. Mater. Process. Technol. 262, 577 (2018)

    Article  CAS  Google Scholar 

  39. J. Rao, J. Zhang, R. Liu, J. Zheng, D. Yin, Mater. Sci. Eng. A 728, 72 (2018)

    Article  CAS  Google Scholar 

  40. S. Dezecot, V. Maurel, J. Buffiere, F. Szmytka, A. Koster, Acta Mater. 123, 24 (2017)

    Article  CAS  Google Scholar 

  41. G. Liu, J. Xiong, L. Tang, Addit. Manuf. 35, 101375 (2020)

    CAS  Google Scholar 

  42. E. Lordan, J. Lazaro-Nebreda, Y. Zhang, K. Dou, P. Blake, Z. Fan, Mater. Sci. Eng. A 778, 139107 (2020)

    Article  CAS  Google Scholar 

  43. Z. Yu, T. Yuan, M. Xu, H. Zhang, X. Jiang, S. Chen, J. Manuf. Process. 62, 430 (2021)

    Article  Google Scholar 

  44. Z. Qi, B. Qi, B. Cong, H. Sun, G. Zhao, J. Ding, J. Manuf. Process. 40, 27 (2019)

    Article  Google Scholar 

  45. Q. Tan, J. Zhang, Q. Sun, Z. Fan, G. Li, Y. Yin, Y. Liu, M. Zhang, Acta Mater. 196, 1 (2020)

    Article  CAS  Google Scholar 

  46. J.H. Martin, B.D. Yahata, J.M. Hundley, J.A. Mayer, T.A. Schaedler, T.M. Pollock, Nature 549, 365 (2017)

    Article  CAS  Google Scholar 

Download references

Acknowledgements

Y. Guo acknowledges the financial support of the China Postdoctoral Science Foundation (No. 2021M690384) and the Beijing Institute of Technology Research Fund Program for Young Scholars.

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Beijing Institute of Technology, Beijing, 100081, China

    Yueling Guo, Jiping Lu & Changmeng Liu

  2. School of Materials Science and Engineering, Beijing Institute of Technology, Beijing, 100081, China

    Qifei Han, Jinlong Hu, Xinghai Yang & Junsheng Wang

  3. Center for Micro and Nano Technologies, Beijing Institute of Technology, Beijing, 100081, China

    Pengcheng Mao

  4. Advanced Research Institute of Multidisciplinary Science, Beijing Institute of Technology, Beijing, 100081, China

    Junsheng Wang

  5. Beijing Hangxing Machinery Manufacturing Co., Ltd,, Beijing, 100013, China

    Shaobo Sun & Zhi He

Authors
  1. Yueling Guo
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Qifei Han
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jinlong Hu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Xinghai Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Pengcheng Mao
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Junsheng Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Shaobo Sun
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Zhi He
    View author publications

    You can also search for this author in PubMed Google Scholar

  9. Jiping Lu
    View author publications

    You can also search for this author in PubMed Google Scholar

  10. Changmeng Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Yueling Guo or Changmeng Liu.

Additional information

Available online at http://link.springer.com/journal/40195.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Guo, Y., Han, Q., Hu, J. et al. Comparative Study on Wire-Arc Additive Manufacturing and Conventional Casting of Al–Si Alloys: Porosity, Microstructure and Mechanical Property. Acta Metall. Sin. (Engl. Lett.) 35, 475–485 (2022). https://doi.org/10.1007/s40195-021-01314-1

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40195-021-01314-1

Keywords

Search

Navigation