Processibility of Al5356 wire on Al6082 substrate by WAAM using MIGwelding power

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This research explores the feasibility of fabricating Al5356 alloy components on an Al6082 substrate via Wire Arc Additive Manufacturing (WAAM) integrated with MIG welding, emphasizing thermal management and post-processing effects. By systematically adjusting parameters such as scanning speed, voltage, and current, single beads, multi-layered overlaps, and a 42-layer vertical structure were produced. A water-cooling system was implemented to counteract heat accumulation, significantly improving dimensional stability and reducing porosity. Microstructural evaluations highlighted gradient grain formation: rapid cooling at the substrate interface yielded fine equiaxed grains, while progressive heat accumulation in upper regions promoted coarser columnar structures. Mechanical assessments revealed enhanced hardness in lower sections (74.06 HV) and tensile strengths (263.81 MPa UTS, 162.97 MPa YS) aligning with conventional as-cast Al5356. Post-build T6 heat treatment elevated average hardness to 75.78 HV but maintained comparable tensile performance to untreated samples. Computational simulations using Simufact software corroborated experimental thermal profiles, demonstrating how cyclic heating influences grain evolution. The study establishes that precise control of thermal dynamics and cooling strategies is pivotal for optimizing microstructure homogeneity and mechanical integrity in aluminium WAAM components.