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Effect of Cold Metal Transfer Mix Synchro-Pulse Process on the Overall Morphology, Microstructure and Mechanical Properties of Wire+ Arc Additively Manufactured AA2219 Alloy

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Abstract

The difference in droplet transfer behavior between the traditional cold metal transfer plus pulse (CMT + P) process and the new CMT mix synchro-pulse (CMT + SP) process, and its effect on the overall morphology, porosity, microstructure and mechanical properties of WAAM-ed AA2219 alloy are studied. Compared to the pulse stage (fP = 160 Hz) of the traditional CMT + P process, the pulse stage of CMT + SP process consists of the low-frequency pulse and high-frequency pulse (HFP) stages. The high frequency (fH = 200 Hz) of the HFP stages formed a high arc force, enlarging the molten pool and enhancing the convection of molten pool. This increased the melting depth between passes and facilitated the flow of the molten pool to the sides and escaping of the pores. As a result, a highly symmetric WAAM-ed AA2219 alloy with a high effective height (14.2 mm) and effective area (89.6 mm2), and low porosity (0.6 ± 0.2%) was manufactured by the CMT + SP process. Moreover, the fine grains (61 μm) with a 43% (area fraction) equiaxed grains were obtained with the CMT + SP process, leading to more θ′ phases precipitating. Thus, the average microhardness and tensile strength of the CMT + SP samples increased to 80.2 ± 6.7 HV and 265.0 ± 17.0 MPa, respectively.

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Acknowledgements

This work was supported by the Joint Funds of the National Natural Science Foundation of China (No. U1864209); the “Qinglan” Project of Jiangsu Province; and the Postgraduate Research & Practice Innovation Program of Jiangsu Province (KYCX21_2951).

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Authors and Affiliations

  1. School of Iron and Steel, Soochow University, Suzhou, 215021, China

    Xiaming Chen, Xiaonan Wang & Hiromi Nagaumi

  2. High-Performance Metal Structural Materials Research Institute, Soochow University, Suzhou, 215021, China

    Xiaming Chen & Hiromi Nagaumi

  3. State Key Laboratory of Rolling and Automation, Northeastern University, Shenyang, 110819, China

    Pengchen Huan

  4. School of Rail Transportation, Soochow University, Suzhou, 215021, China

    Zengrong Hu & Zhikang Wu

  5. Shandong Weiqiao Pioneering Group Co., Ltd, Binzhou, 256200, China

    Bo Zhang

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  1. Xiaming Chen
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Chen, X., Wang, X., Huan, P. et al. Effect of Cold Metal Transfer Mix Synchro-Pulse Process on the Overall Morphology, Microstructure and Mechanical Properties of Wire+ Arc Additively Manufactured AA2219 Alloy. Met. Mater. Int. 29, 552–563 (2023). https://doi.org/10.1007/s12540-022-01240-6

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