Mechanical and metallurgical study of ER-4043 aluminum alloy using wire arc additive manufacturing

Abstract

Additive manufacturing, particularly wire arc additive manufacturing (WAAM), has gained significant attention in recent years as a promising technology for producing complex metal components. This study focuses on the investigation of the mechanical and metallurgical properties of components fabricated from ER-4043 aluminum alloy using WAAM. The research encompasses a comprehensive examination of the microstructure, mechanical performance, and metallurgical characteristics of WAAM-produced ER-4043 aluminum alloy samples. The WAAM process parameters, including wire feed rate, arc voltage, and deposition speed, are systematically optimized to achieve desirable material properties. Microstructural analysis reveals the presence of various phases and grain structures within the WAAM-fabricated ER-4043 aluminum alloy, and the impact of process parameters on these structures is assessed. Mechanical properties such as tensile strength, hardness, and fatigue behavior are investigated to evaluate the performance of the produced components. Furthermore, metallurgical characteristics, including intermetallic formation, porosity, and elemental composition, are thoroughly studied to understand the alloy's behavior during WAAM processing. This investigation sheds light on the effects of process parameters on microstructure and mechanical properties, providing valuable insights for optimizing ER-4043 aluminum alloy fabrication using WAAM. Ultimately, this research contributes to a deeper understanding of the mechanical and metallurgical aspects of ER-4043 aluminum alloy manufactured through WAAM, facilitating its application in various industries such as aerospace, automotive, and marine, where lightweight, high-strength aluminum components are in demand.