Wire Arc Additive Manufacturing of Aluminium Alloys

Ouellet, T.; Croteau, M.; Bois-Brochu, A.; Lévesque, J. (2023). Wire Arc Additive Manufacturing of Aluminium Alloys. Eng. Proc. 2023, 43(1).


Additive manufacturing is used to produce parts with complex near-net shape geometries. It can also be used to repair parts that have worn out in service using specific processes such as Wire Arc Additive Manufacturing (WAAM) and Directed Energy Deposition (DED). Wire additive manufacturing processes allow for relatively high deposition rates compared to powder technologies but necessitate a stable welding process and a controlled heat input. As the perfect transfer mode for low welding energy and low spatter, Cold Metal Transfer (CMT) is the process of choice for WAAM. In this project, parts made from aluminium 4943 and 6061 were additively manufactured using CMT technology. The deposition rate, porosity level, and mechanical properties are discussed herein. For the 6061 alloy, after heat treatment, it is possible to attain properties that are close to those obtained for T6 for wrought products or even higher when samples are hot-isostatically pressed.