Effects of ultrasonic rotating extrusion assisted wire arc additive manufacturing on the microstructure and mechanical properties of 5356 aluminum alloy
Wire Arc Additive Manufacturing (WAAM) for the fabrication of lightweight Al alloy represents a burgeoning area of research. Despite this, the presence of porosity defects, coarse surface grain sizes, and the clustering of precipitated phases in WAAM-produced Al alloy samples have been identified as...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-03-01
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| Series: | Ultrasonics Sonochemistry |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S1350417725000197 |
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| author | Rongtao Zhu Liang Zhang Longhan Duan Zhaofeng Liang Chuang Li Bo Yuan Peng Du Zhiwen Xie Yaping Zhang |
| author_facet | Rongtao Zhu Liang Zhang Longhan Duan Zhaofeng Liang Chuang Li Bo Yuan Peng Du Zhiwen Xie Yaping Zhang |
| author_sort | Rongtao Zhu |
| collection | DOAJ |
| description | Wire Arc Additive Manufacturing (WAAM) for the fabrication of lightweight Al alloy represents a burgeoning area of research. Despite this, the presence of porosity defects, coarse surface grain sizes, and the clustering of precipitated phases in WAAM-produced Al alloy samples have been identified as detrimental to their mechanical properties, rendering them inadequate for contemporary service requirements. In this investigation, an innovative approach termed Ultrasonic-Rotating Extrusion-Wire Arc Additive Manufacturing (U-RE-WAAM) was proposed, which integrates the synergistic effects of ultrasonic and mechanical force fields into the WAAM process. Comparative analysis were conducted on defects, microstructure and mechanical properties between WAAM and U-RE-WAAM samples to investigate the impact of U-RE-WAAM on aluminum alloy samples. The results show that the mechanical force field causes a large amount of plastic deformation, which refines the grain size and restructures the precipitation phase from clustered aggregates to a fine dispersion. Furthermore, the U-RE-WAAM process achieves a reduction in porosity and an enhancement in grain size and precipitated phase distribution by the coupling of mechanical force field and ultrasonic energy field. Consequently, the mechanical properties of U-RE-WAAM samples are markedly superior, with a 32.8% increase in hardness and significant improvements in yield strength 81%, ultimate tensile strength 41%, and elongation 38.9%. |
| format | Article |
| id | doaj-art-373720b0e9ee4b73a5c402c876f50a50 |
| institution | Kabale University |
| issn | 1350-4177 |
| language | English |
| publishDate | 2025-03-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Ultrasonics Sonochemistry |
| spelling | doaj-art-373720b0e9ee4b73a5c402c876f50a502025-02-07T04:47:16ZengElsevierUltrasonics Sonochemistry1350-41772025-03-01114107240Effects of ultrasonic rotating extrusion assisted wire arc additive manufacturing on the microstructure and mechanical properties of 5356 aluminum alloyRongtao Zhu0Liang Zhang1Longhan Duan2Zhaofeng Liang3Chuang Li4Bo Yuan5Peng Du6Zhiwen Xie7Yaping Zhang8School of Mechanical Engineering and Automation, University of Science and Technology Liaoning, Anshan 114051, China; Institute of Intelligent Manufacturing Technology, Shenzhen Polytechnic University, Shenzhen 518055, ChinaInstitute of Intelligent Manufacturing Technology, Shenzhen Polytechnic University, Shenzhen 518055, China; Corresponding author.School of Mechanical Engineering and Automation, University of Science and Technology Liaoning, Anshan 114051, China; Institute of Intelligent Manufacturing Technology, Shenzhen Polytechnic University, Shenzhen 518055, ChinaInstitute of Intelligent Manufacturing Technology, Shenzhen Polytechnic University, Shenzhen 518055, ChinaSchool of Mechanical Engineering and Automation, University of Science and Technology Liaoning, Anshan 114051, China; Institute of Intelligent Manufacturing Technology, Shenzhen Polytechnic University, Shenzhen 518055, ChinaInstitute of Intelligent Manufacturing Technology, Shenzhen Polytechnic University, Shenzhen 518055, ChinaInstitute of Intelligent Manufacturing Technology, Shenzhen Polytechnic University, Shenzhen 518055, ChinaSchool of Mechanical Engineering and Automation, University of Science and Technology Liaoning, Anshan 114051, ChinaInstitute of Intelligent Manufacturing Technology, Shenzhen Polytechnic University, Shenzhen 518055, ChinaWire Arc Additive Manufacturing (WAAM) for the fabrication of lightweight Al alloy represents a burgeoning area of research. Despite this, the presence of porosity defects, coarse surface grain sizes, and the clustering of precipitated phases in WAAM-produced Al alloy samples have been identified as detrimental to their mechanical properties, rendering them inadequate for contemporary service requirements. In this investigation, an innovative approach termed Ultrasonic-Rotating Extrusion-Wire Arc Additive Manufacturing (U-RE-WAAM) was proposed, which integrates the synergistic effects of ultrasonic and mechanical force fields into the WAAM process. Comparative analysis were conducted on defects, microstructure and mechanical properties between WAAM and U-RE-WAAM samples to investigate the impact of U-RE-WAAM on aluminum alloy samples. The results show that the mechanical force field causes a large amount of plastic deformation, which refines the grain size and restructures the precipitation phase from clustered aggregates to a fine dispersion. Furthermore, the U-RE-WAAM process achieves a reduction in porosity and an enhancement in grain size and precipitated phase distribution by the coupling of mechanical force field and ultrasonic energy field. Consequently, the mechanical properties of U-RE-WAAM samples are markedly superior, with a 32.8% increase in hardness and significant improvements in yield strength 81%, ultimate tensile strength 41%, and elongation 38.9%.http://www.sciencedirect.com/science/article/pii/S13504177250001975356 aluminum alloyWire arc additive manufacturingMicrostructure evolutionUltrasonic rotating extrusion |
| spellingShingle | Rongtao Zhu Liang Zhang Longhan Duan Zhaofeng Liang Chuang Li Bo Yuan Peng Du Zhiwen Xie Yaping Zhang Effects of ultrasonic rotating extrusion assisted wire arc additive manufacturing on the microstructure and mechanical properties of 5356 aluminum alloy Ultrasonics Sonochemistry 5356 aluminum alloy Wire arc additive manufacturing Microstructure evolution Ultrasonic rotating extrusion |
| title | Effects of ultrasonic rotating extrusion assisted wire arc additive manufacturing on the microstructure and mechanical properties of 5356 aluminum alloy |
| title_full | Effects of ultrasonic rotating extrusion assisted wire arc additive manufacturing on the microstructure and mechanical properties of 5356 aluminum alloy |
| title_fullStr | Effects of ultrasonic rotating extrusion assisted wire arc additive manufacturing on the microstructure and mechanical properties of 5356 aluminum alloy |
| title_full_unstemmed | Effects of ultrasonic rotating extrusion assisted wire arc additive manufacturing on the microstructure and mechanical properties of 5356 aluminum alloy |
| title_short | Effects of ultrasonic rotating extrusion assisted wire arc additive manufacturing on the microstructure and mechanical properties of 5356 aluminum alloy |
| title_sort | effects of ultrasonic rotating extrusion assisted wire arc additive manufacturing on the microstructure and mechanical properties of 5356 aluminum alloy |
| topic | 5356 aluminum alloy Wire arc additive manufacturing Microstructure evolution Ultrasonic rotating extrusion |
| url | http://www.sciencedirect.com/science/article/pii/S1350417725000197 |
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