Investigation of the effect of process parameters on porosity, microstructure and mechanical properties of Al–5 Mg alloy test samples fabricated by wire arc additive manufacturing

Abstract

Wire arc additive manufacturing (WAAM) of aluminium alloy components has gained a lot of importance due to its ease of production of complex parts. However, its widespread acceptance as replacement for conventional manufacturing processes remains contested. The occurrence of defects, particularly porosity in products manufactured by WAAM remains a dominant reason for its lack of adoption. The gas flow rate, feed rate of wire, work piece and deposition voltage are some of the process parameters that affect the evolution of the porosity. The use of optimal process parameters is essential in obtaining defect-free aluminium products. In the present work, Al–5 Mg alloy was selected to investigate the role of WAAM process parameters on the product quality. The argon gas flow rates and wire feed rates were varied between 8–4 l/min and 3.6–4.7 mm/min, respectively. Melt deposition voltages were varied between 13 and 19.5 V. Microstructural studies using scanning electron microscopy and transmission electron microscopy were carried out to assess the effect of the process parameters on the quality of the product. The specimens were also subjected to mechanical testing. Microstructural analysis and mechanical testing results indicated that the optimal process parameters for producing defect-free products through wire arc additive manufacturing were a gas flow rate of 10 l/min, a wire feed rate of 4 m/min, and a deposition voltage of 14V. © The Author(s), under exclusive licence to Springer Nature Switzerland AG 2024.