Metal additive manufacturing: Technology, metallurgy and modelling

The mechanical properties and microstructural features of aluminum 5083 (AI5083) weldments processed by gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW) are investigated. Weldments processed by both methods are mechanically softer than the parent material AI5083, and could be potential sites for plastic localization. It is revealed that AI5083 weldments processed by GTAW are mechanical more reliable than those by GMAW. The former bears higher strength, more ductility, and no apparent microstructure defects. Perceivable porosity in weldments by GMAW is found, which could account for the distinct mechanical properties between weldments processed by GTAW and GMAW. It is suggested that caution should be exercised when using GMAW for AI5083 in the high-speed-train industry where such light weight metal is broadly used.

Microstructure and mechanical properties of aluminum 5083 weldments by gas tungsten arc and gas metal arc welding

The present study investigates the effect of laser peening without coating on aluminum alloy Al-6061-T6 with a 300 mJ infrared laser The surface topography, microstructure, surface topography, surface residual stress and micro-hardness of peened and unpeened surfaces were studied The study shows that laser peening without coating can significantly improve surface compressive stress and micro-hardness with trivial increase in surface roughness Microstructure evaluation confirmed there was no near surface solidification after LPwC

Laser peening without coating on aluminum alloy Al-6061-T6 using low energy Nd:YAG laser

Effect of laser shock peening on the hardness of AL-7075 alloy

Accurate temperature measurements based on careful experimentation and microstructural analysis were conducted for Ti-6Al-4V and Inconel 625 alloys deposited using the laser-based directed energy deposition process. In the case of the Ti-6Al-4V alloy, thermal measurements were made in the first layer during the first and four subsequent deposits to ascertain microstructural evolution during the heating and cooling cycles. Four energy densities were utilized during deposition of the Inconel 625 alloy to alter cooling rates and determine the impact of processing conditions on solidification morphology. The precise experimental measurements enabled a comprehensive analysis of the solid state reactions for Ti-6Al-4V, and the solidification phenomena to be elucidated for Inconel 625. The results for the Ti-6Al-4V alloy indicated that the measured thermal response could be used to anticipate initial microstructure based on cooling rates from the β-transus, and subsequent thermal cycles could be utilized to define potential transformations between α, α′, and β. Analysis of the measured thermal cycles from the liquid through solidification for the Inconel 625 alloy showed that processing parameters could be linked to factors governing the solidification process and microstructural features. Using these relationships, an accurate processing map for laser-based directed energy deposition for Inconel 625 was constructed to enable the identification of solidification morphology and microstructural scale based on critical processing parameters.

Thermal and microstructural analysis of laser-based directed energy deposition for Ti-6Al-4V and Inconel 625 deposits

Corrosion fatigue behaviour of aluminium alloy 6061-T651 welded using fully automatic gas metal arc welding and ER5183 filler alloy

Effect of Nb content on the microstructure and mechanical properties of binary Ti-Nb alloys

Semi-automatic and automatic pulsed gas metal arc welding (GMAW) of aluminium alloy 5083 with ER5356 filler wire causes considerable softening in the weld. The tensile strength of dressed automatic welds approaches that of the base metal, but the stress concentration caused by the weld toe in undressed semi-automatic welds reduced the tensile strength significantly. Fully automatic welds displayed improved fatigue properties compared to semi-automatic welds.

Mechanical properties of 5083 aluminium welds after manual and automatic pulsed gas metal arc welding using E5356 filler

Aluminium and its alloys are widely used as engineering materials on account of their low density, high strength-to-weight ratios, excellent formability and good corrosion resistance in many environments. This investigation focused on one popular wrought aluminium alloy, namely magnesium-alloyed 5083 (in the strain hardened -H111 temper state). Aluminium alloy 5083 is one of the highest strength non-heat treatable aluminium alloys, with excellent corrosion resistance, good weldability and reduced sensitivity to hot cracking when welded with near-matching magnesium-alloyed filler metal. This alloy finds applications in ship building, automobile and aircraft structures, tank containers, unfired welded pressure vessels, cryogenic applications, transmission towers, drilling rigs, transportation equipment, missile components and armour plates. In many of these applications welded structures of aluminium are exposed to aqueous environments throughout their lifetimes. Welding is known to introduce tensile residual stresses, to promote grain growth, recrystallization and softening in the heat-affected zone, and to cause weld defects that act as stress concentrations and preferential fatigue crack initiation sites. Fatigue studies also emphasised the role of precipitates, second phase particles and inclusions in initiating fatigue cracks. When simultaneously subjected to a corrosive environment and dynamic loading, the fatigue properties are often adversely affected and even alloys with good corrosion resistance may fail prematurely under conditions promoting fatigue failure. The good corrosion resistance of the aluminium alloys is attributed to the spontaneous formation of a thin, compact and adherent aluminium oxide film on the surface on exposure to water or air. This hydrated aluminium oxide layer may, however, dissolve in some chemical solutions, such as strong acids or alkaline solutions. Damage to this passive layer in chloride-containing environments (such as sea water or NaCl solutions), may result in localised corrosive attack such as pitting corrosion. The presence of corrosion pits affects the fatigue properties of the aluminium alloys by creating sharp surface stress concentrations which promote fatigue crack initiation. In welded structures, pits are often associated with coarse second phase particles or welding defects [1-4].

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Corrosion Fatigue Behaviour of Aluminium 5083-H111 Welded Using Gas Metal Arc Welding Method

Copyright: 2013 SAIMM. Published in Journal of The Southern African Institute of Mining and Metallurgy, vol. 113(4), pp 357-361

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Kalenda Mutombo

Papers

Corrosion fatigue behaviour of aluminium alloy 6061-T651 welded using fully automatic gas metal arc welding and ER5183 filler alloy

Effect of Nb content on the microstructure and mechanical properties of binary Ti-Nb alloys

Mechanical properties of 5083 aluminium welds after manual and automatic pulsed gas metal arc welding using E5356 filler

Corrosion Fatigue Behaviour of Aluminium 5083-H111 Welded Using Gas Metal Arc Welding Method

Alpha case formation mechanism in Ti-6Al-4V alloy investment castings using YFSZ shell moulds