Mechanical properties and corrosion behavior of wire Arc additive manufactured ER5356 Al alloys

Abstract

This detailed study explores the complex information of ER5356 Aluminium alloy wall manufactured via Wire Arc Additive Manufacturing (WAAM) process. By comparing the findings with existing literature, the importance of precise control over process parameters for optimizing both alloy performance and additive manufacturing practices was highlighted. This investigation includes a complex metallographic analysis which begins with an in-depth examination of the microstructure. The metallographic preparation was done by deploying Weck's reagent, Pulton's reagents and Keller’s reagent as an etchant and the efforts led to successful microstructure examination by achieving crystal-clear insights into grain structures of the specimens. Also EDS analysis and EBSD analysis was used to measure phase compositions and the average grain size of different regions from the wall. Mechanical property evaluation was performed including Vickers hardness testing and tensile testing to understand the performance of WAAM Al alloy samples. WAAM Al alloy samples were further subjected to High pressure torsion and analyzed further to understand the effect of severe plastic deformation of HPT on WAAM Al alloys. Corrosion resistance was examined closely through nitric acid mass loss test and potentiodynamic polarization tests, shedding light on the effect of beta phase content. This research expanded understanding of ER5356 alloy behavior in the WAAM context, providing valuable insights for the future of additive manufacturing and the potential applications of this alloy across diverse industries.