Porosity in cored-wire-arc directed energy deposition of TiC/Al composite: formation mechanism and inhibition strategy
Porosity is an unavoidable problem in aluminium alloy wire-arc directed energy deposition (DED), becoming even more prominent in aluminium-matrix powder core wires, which significantly limits their performance and application potential. This study combines wire-arc DED technology with Al-matrix powd...
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Taylor & Francis Group
2025-12-01
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| Series: | Virtual and Physical Prototyping |
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| Online Access: | https://www.tandfonline.com/doi/10.1080/17452759.2024.2449169 |
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| author | Liu Yang Hao Yi Le Jia Huajun Cao |
| author_facet | Liu Yang Hao Yi Le Jia Huajun Cao |
| author_sort | Liu Yang |
| collection | DOAJ |
| description | Porosity is an unavoidable problem in aluminium alloy wire-arc directed energy deposition (DED), becoming even more prominent in aluminium-matrix powder core wires, which significantly limits their performance and application potential. This study combines wire-arc DED technology with Al-matrix powder cored wire for the first time, successfully fabricating monolayer and multilayer composite components using a custom-designed TiC/Al-matrix powder core wire. The pore types and formation mechanisms in cored-wire-arc DED TiC/Al composites were systematically investigated. The findings indicate that: (1) Compared to conventional aluminium alloys, the Al-matrix powder core wire exhibited larger pores and higher porosity. Additionally, a novel pore type, enclosed by Ti and Si elements, was identified. (2) Pores concentrate near specimen edges due to the migration, aggregation, and prolonged stabilisation of large bubbles in the melt pool. (3) To mitigate porosity, strategies of spiral arc oscillation (SO) and ultrasonic vibration assisted (UA) was innovatively introduced, which effectively reducing porosity levels. SO enhances melt pool flow, reducing porosity by 47% relative to as-deposited (AD) specimens. UA induces cavitation effects and acoustic flow, enhancing Marangoni flow and reducing porosity by 63% in SO + UA specimens. This study presents a novel approach for high-performance aluminium-matrix composite fabrication. |
| format | Article |
| id | doaj-art-8845f44d6e0c4aa299eb9430f4d65553 |
| institution | Kabale University |
| issn | 1745-2759 1745-2767 |
| language | English |
| publishDate | 2025-12-01 |
| publisher | Taylor & Francis Group |
| record_format | Article |
| series | Virtual and Physical Prototyping |
| spelling | doaj-art-8845f44d6e0c4aa299eb9430f4d655532025-01-08T21:07:57ZengTaylor & Francis GroupVirtual and Physical Prototyping1745-27591745-27672025-12-0120110.1080/17452759.2024.2449169Porosity in cored-wire-arc directed energy deposition of TiC/Al composite: formation mechanism and inhibition strategyLiu Yang0Hao Yi1Le Jia2Huajun Cao3State Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing, People’s Republic of ChinaState Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing, People’s Republic of ChinaState Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing, People’s Republic of ChinaState Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing, People’s Republic of ChinaPorosity is an unavoidable problem in aluminium alloy wire-arc directed energy deposition (DED), becoming even more prominent in aluminium-matrix powder core wires, which significantly limits their performance and application potential. This study combines wire-arc DED technology with Al-matrix powder cored wire for the first time, successfully fabricating monolayer and multilayer composite components using a custom-designed TiC/Al-matrix powder core wire. The pore types and formation mechanisms in cored-wire-arc DED TiC/Al composites were systematically investigated. The findings indicate that: (1) Compared to conventional aluminium alloys, the Al-matrix powder core wire exhibited larger pores and higher porosity. Additionally, a novel pore type, enclosed by Ti and Si elements, was identified. (2) Pores concentrate near specimen edges due to the migration, aggregation, and prolonged stabilisation of large bubbles in the melt pool. (3) To mitigate porosity, strategies of spiral arc oscillation (SO) and ultrasonic vibration assisted (UA) was innovatively introduced, which effectively reducing porosity levels. SO enhances melt pool flow, reducing porosity by 47% relative to as-deposited (AD) specimens. UA induces cavitation effects and acoustic flow, enhancing Marangoni flow and reducing porosity by 63% in SO + UA specimens. This study presents a novel approach for high-performance aluminium-matrix composite fabrication.https://www.tandfonline.com/doi/10.1080/17452759.2024.2449169Wire-arc directed energy depositioncomposite partsporosityformation mechanismsspiral arc oscillationultrasonic vibration |
| spellingShingle | Liu Yang Hao Yi Le Jia Huajun Cao Porosity in cored-wire-arc directed energy deposition of TiC/Al composite: formation mechanism and inhibition strategy Virtual and Physical Prototyping Wire-arc directed energy deposition composite parts porosity formation mechanisms spiral arc oscillation ultrasonic vibration |
| title | Porosity in cored-wire-arc directed energy deposition of TiC/Al composite: formation mechanism and inhibition strategy |
| title_full | Porosity in cored-wire-arc directed energy deposition of TiC/Al composite: formation mechanism and inhibition strategy |
| title_fullStr | Porosity in cored-wire-arc directed energy deposition of TiC/Al composite: formation mechanism and inhibition strategy |
| title_full_unstemmed | Porosity in cored-wire-arc directed energy deposition of TiC/Al composite: formation mechanism and inhibition strategy |
| title_short | Porosity in cored-wire-arc directed energy deposition of TiC/Al composite: formation mechanism and inhibition strategy |
| title_sort | porosity in cored wire arc directed energy deposition of tic al composite formation mechanism and inhibition strategy |
| topic | Wire-arc directed energy deposition composite parts porosity formation mechanisms spiral arc oscillation ultrasonic vibration |
| url | https://www.tandfonline.com/doi/10.1080/17452759.2024.2449169 |
| work_keys_str_mv | AT liuyang porosityincoredwirearcdirectedenergydepositionofticalcompositeformationmechanismandinhibitionstrategy AT haoyi porosityincoredwirearcdirectedenergydepositionofticalcompositeformationmechanismandinhibitionstrategy AT lejia porosityincoredwirearcdirectedenergydepositionofticalcompositeformationmechanismandinhibitionstrategy AT huajuncao porosityincoredwirearcdirectedenergydepositionofticalcompositeformationmechanismandinhibitionstrategy |