Modified microstructure and enhanced mechanical performance of wire arc additive manufactured 2319 aluminum alloy via interlayer friction stir processing

Abstract

In order to eliminate metallurgical defects and improve mechanical properties of the builds, the interlayer friction stir processing (FSP) technology was employed to assist in wire-arc additive manufacturing (WAAM) high-strength 2319 aluminium alloy, and comprehensive analysis was investigated on the microstructural evolution and mechanical properties. The grains at the bottom of the builds grew, and the proportion of recrystallized grains increased due to cyclic thermal influence, resulting in a more isotropic microstructure. By applying interlayer FSP to WAAM, the coarse columnar grains in the top regions were refined by 95%, and proportion of high angle grain boundaries (HABs) increased by 24.92 times, effectively reducing the dislocation density. During friction stir processing, the precipitation phase was fragmented, thereby providing a pinning effect that hinders dislocation accumulation. With an increase in plastic deformation, the dislocation density increased, triggering dynamic recrystallisation. Additionally, the mechanical properties of the builds prepared using hybrid method were assessed. The as-deposited builds exhibited an average ultimate tensile strength (UTS) and elongation (EL) of 225 MPa and 7.2%, respectively. By contrast, the tensile properties of stirring builds in the stable region were increased, with an average ultimate tensile strength (UTS) and elongation (EL) of 248.5 MPa and 12.7% respectively. In summary, this work provides practical guidelines for optimizing the additive manufacturing quality of high-strength aluminium alloys.

Keywords

2319 aluminium alloy / wire-arc additive manufacturing / friction stir processing / microstructure evolution / mechanical properties

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