Abstract
This study investigates deposition of different aluminum alloys and the influence of added elements on their mechanical properties. Focusing on wire and arc additive manufacturing (WAAM), this study aimed to address the constraints of conventional fabrication, particularly in the context of multi-material applications. WAAM was utilized for the precise deposition of 5000 series aluminum alloys onto robust 7000 series counterparts, and the results were analyzed to characterize dissimilar aluminum alloy interactions. The deposition process employed an advanced WAAM system equipped with an industrial robot, dual-axis positioner, and cold metal transfer welder, coupled with A5356 wires and A5052/A7075 plates as materials. Elemental analyses, hardness tests, tensile testing and Corrosion Testing were performed, revealing a distinct transition layer, which indicates an interplay between dissimilar alloys during deposition. Heat treatment not only restored the hardness of the 7000 series alloy, but also increased its corrosion resistance. The resulting tensile strength surpasses common 5000 series aluminum alloy benchmarks. The study evaluates interfaces under accuracy considerations, highlighting the practical applications of dissimilar aluminum alloy additive manufacturing.
