Enhancing Mechanical Properties: Exploring the Effect of Annealing Temperature on Wire Arc Additively Manufactured High-Strength Steel

This study investigates the mechanical properties of exceptionally high-strength steel produced by wire and arc additive manufacturing (WAAM), using the 304 stainless steel wire and the low carbon wire (LCS). The study found that annealing treatment can enhance the steel's mechanical properties. The microstructure in the LCS layer changed from ferrite to bainite and then to a mixture of austenite, pearlite, and bainite with increasing annealing temperature. In contrast, the SS layer retained its martensitic structure, albeit with altered lath sizes. The annealing treatment also improved the orientation of the grains in the steel. The optimal annealing temperature observed for the steel was 900 ℃, which resulted in a maximum tensile strength of 1176 MPa along the Y direction and 1255 MPa along the Z direction. Despite the superior mechanical properties, the LCS layer still exhibited failure during tensile testing due to its lower hardness. The study suggests that annealing treatment can be a useful technique for enhancing the mechanical properties of high-strength steel in WAAM applications.

Investigation of In Situ Vibration During Wire and Arc Additive Manufacturing

Wire and arc additive manufacturing (WAAM) is becoming a promising technique due to its high deposition rate and low cost. However, WAAM faces challenges of coarse grains. In this study, a novel in situ vibration method was proposed to suppress these imperfections of WAAM. Temperature and vibration distributions were explored first, and the optimized parameters were utilized for manufacturing low-carbon steel parts. The results revealed that after the vibration, the average grain size in fine grain zone was reduced from 9.8 to 7.1 μm, and that in coarse grain zone was declined from 10.6 to 7.4 μm, respectively. No large deformation occurred due to the low temperature. Grain refining was attributed to more dendrite fragments induced by excessive stress at the roots of dendrites. The refined grains enhanced mechanical strength of the parts in both X and Z directions and improved the average hardness. After the vibration, the ultimate tensile strength and yield strength were increased to 522.5 and 395 MPa, which represented an increase of 10% and 13.8%, respectively. The average hardness was improved to 163 HV, which was an increase of 10.1%.

Microstructure Evaluation of the Potential of Additive Manufactured Dissimilar Titanium-Aluminum Alloys

Pure titanium (Ti) ERTi-2 was accumulated on an aluminum (Al) alloy ER5356 component via wire and arc additive manufacturing. The effect of processing parameters, mainly the input heat per unit length, on Ti/Al components was investigated. The microstructure of the Ti deposited layer and the Ti/Al reaction layer was analyzed using optical microscopy, scanning electron microscope, energy-dispersive spectroscopy, and an X-ray diffractometer. The fabrication of the surface layer equivalent to pure Ti as the used wire or Ti-Al alloy on the Al alloy components was achieved under low and high input heat conditions, respectively, although the Ti/Al components had low joinability and cracks at the reaction layer. Finally, the potential of additive-manufactured Ti/Al components with reference to our results and previous reports was discussed.

Effects of In-Process Ultrasonic Vibration on Weld Formation and Grain Size of Wire and Arc Additive Manufactured Parts

Wire and arc additive manufacturing (WAAM) is a competitive technique, which enables the fabrication of medium and large metallic components. However, due to the presence of coarse columnar grains in the additively manufactured parts, the resultant mechanical properties will be reduced, which limits the application of WAAM processes in the engineering fields. Grain refinement and improved mechanical properties can be achieved by introducing ultrasonic vibration. Herein, we applied ultrasonic vibration to the WAAM process and investigated the effects of wire feed speed, welding speed, and ultrasonic amplitude on the weld formation and grain size during ultrasonic vibration. Finally, a regression model between the average grain size and wire feed speed, welding speed, and ultrasonic amplitude was established. The results showed that due to the difference in heat input and cladding amount, wire feed speed, welding speed, and ultrasonic amplitude have a significant influence on the weld width and reinforcement. Excessive ultrasonic amplitude could cause the weld to crack during spreading. The average grain size increased with increasing wire feed speed and decreasing welding speed. With increasing ultrasonic amplitude, the average grain size exhibited a trend of decreasing first and then increasing. This would be helpful to manufacture parts of the required grain size in ultrasonic vibration-assisted WAAM fields.

Microstructure and Mechanical Properties of AlSi7Mg0.6 Aluminum Alloy Fabricated by Wire and Arc Additive Manufacturing Based on Cold Metal Transfer (WAAM-CMT)

Wire and arc additive manufacturing based on cold metal transfer (WAAM-CMT) has aroused wide public concern in recent years as one of the most advanced technologies for manufacturing components with complex geometries. However, the microstructure and mechanical properties of the parts fabricated by WAAM-CMT technology mostly are intolerable for engineering application and should be improved necessarily. In this study, heat treatment was proposed to optimize the microstructure and enhance mechanical properties in the case of AlSi7Mg0.6 alloy. After heat treatment, the division between coarse grain zone and fine grain zone of as-deposited samples seemed to disappear and the distribution of Si and Mg elements was more uniform. What is more, the yield strength and ultimate tensile strength were improved significantly, while the ductility could be sustained after heat treatment. The improvement of strength is attributed to precipitation strengthening, and the shape change of Si phase. No reduction in ductility is due to the higher work hardening rate caused by nanostructured precipitate. It is proved that heat treatment as an effective method can control the microstructure and enhance comprehensive mechanical properties, which will boost rapid development of WAAM industrial technology.

Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM)

Additive manufacturing has revolutionized the manufacturing paradigm in recent years due to the possibility of creating complex shaped three-dimensional parts which can be difficult or impossible to obtain by conventional manufacturing processes. Among the different additive manufacturing techniques, wire and arc additive manufacturing (WAAM) is suitable to produce large metallic parts owing to the high deposition rates achieved, which are significantly larger than powder-bed techniques, for example. The interest in WAAM is steadily increasing, and consequently, significant research efforts are underway. This review paper aims to provide an overview of the most significant achievements in WAAM, highlighting process developments and variants to control the microstructure, mechanical properties, and defect generation in the as-built parts; the most relevant engineering materials used; the main deposition strategies adopted to minimize residual stresses and the effect of post-processing heat treatments to improve the mechanical properties of the parts. An important aspect that still hinders this technology is certification and nondestructive testing of the parts, and this is discussed. Finally, a general perspective of future advancements is presented.