Arc Additively Manufactured 5356 Aluminum Alloy with Cable-Type Welding Wire: Microstructure and Mechanical Properties

Wire arc additive manufacturing (WAAM) is the latest development in 3D printing because of its high build rate. This study investigated the first use of cable-type welding wire (CWW) to manufacture thin-walled AA5356 aluminum alloy through cold metal transfer technology. The inherent advantages of the CCW, such as high deposition efficiency, energy savings, and better stirring of the weld puddle due to arc rotation, were tapped and analyzed for WAAM. The experimental results showed that WAAM CWW provides enhanced quality built parts. The grain morphology, phase in micro-constituents, and defect formation were investigated through structured optical micrography and XRD analyses. The mechanical test was also performed along and normal to the build direction. The optical microscopy results showed that a defect free deposit with equiaxed grains was formed. Compared with the casting aluminum alloy, the average ultimate tensile strength and yield strength of the parts made by the WAAM with CWW increased by 19.8% and 22.5%, respectively.