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Article

Characterisation of a High-Performance Al–Zn–Mg–Cu Alloy Designed for Wire Arc Additive Manufacturing

1
Instituto de Soldadura e Qualidade, Av. Prof. Dr. Cavaco Silva, 33, 2740-120 Porto Salvo, Portugal
2
LKR Light Metals Technologies Ranshofen, Austrian Institute of Technology, Lamprechtshausenerstraße 61, 5282 Ranshofen-Braunau, Austria
3
SinusPro GmbH, Conrad-von-Hötzendorf-Straße 127, 8010 Graz, Austria
4
MatCalc Engineering GmbH, Gumpendorfer Strasse 21, 1060 Vienna, Austria
5
Institute of Materials Science and Technology, TU Wien, Getreidemarkt 9/E308, 1060 Vienna, Austria
*
Author to whom correspondence should be addressed.
Materials 2020, 13(7), 1610; https://doi.org/10.3390/ma13071610
Received: 5 March 2020 / Revised: 27 March 2020 / Accepted: 30 March 2020 / Published: 1 April 2020
(This article belongs to the Special Issue Progress in Metal Additive Manufacturing and Metallurgy)
Ever-increasing demands of industrial manufacturing regarding mechanical properties require the development of novel alloys designed towards the respective manufacturing process. Here, we consider wire arc additive manufacturing. To this end, Al alloys with additions of Zn, Mg and Cu have been designed considering the requirements of good mechanical properties and limited hot cracking susceptibility. The samples were produced using the cold metal transfer pulse advanced (CMT-PADV) technique, known for its ability to produce lower porosity parts with smaller grain size. After material simulations to determine the optimal heat treatment, the samples were solution heat treated, quenched and aged to enhance their mechanical performance. Chemical analysis, mechanical properties and microstructure evolution were evaluated using optical light microscopy, scanning electron microscopy, energy dispersive X-ray spectroscopy, X-ray fluorescence analysis and X-ray radiography, as well as tensile, fatigue and hardness tests. The objective of this research was to evaluate in detail the mechanical properties and microstructure of the newly designed high-performance Al–Zn-based alloy before and after ageing heat treatment. The only defects found in the parts built under optimised conditions were small dispersed porosities, without any visible cracks or lack of fusion. Furthermore, the mechanical properties are superior to those of commercial 7xxx alloys and remarkably independent of the testing direction (parallel or perpendicular to the deposit beads). The presented analyses are very promising regarding additive manufacturing of high-strength aluminium alloys. View Full-Text
Keywords: wire arc additive manufacturing; precipitation hardening; Al–Zn–Mg–Cu alloys; microstructure characterisation; mechanical properties wire arc additive manufacturing; precipitation hardening; Al–Zn–Mg–Cu alloys; microstructure characterisation; mechanical properties
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MDPI and ACS Style

Morais, P.J.; Gomes, B.; Santos, P.; Gomes, M.; Gradinger, R.; Schnall, M.; Bozorgi, S.; Klein, T.; Fleischhacker, D.; Warczok, P.; Falahati, A.; Kozeschnik, E. Characterisation of a High-Performance Al–Zn–Mg–Cu Alloy Designed for Wire Arc Additive Manufacturing. Materials 2020, 13, 1610. https://doi.org/10.3390/ma13071610

AMA Style

Morais PJ, Gomes B, Santos P, Gomes M, Gradinger R, Schnall M, Bozorgi S, Klein T, Fleischhacker D, Warczok P, Falahati A, Kozeschnik E. Characterisation of a High-Performance Al–Zn–Mg–Cu Alloy Designed for Wire Arc Additive Manufacturing. Materials. 2020; 13(7):1610. https://doi.org/10.3390/ma13071610

Chicago/Turabian Style

Morais, Paulo J., Bianca Gomes, Pedro Santos, Manuel Gomes, Rudolf Gradinger, Martin Schnall, Salar Bozorgi, Thomas Klein, Dominik Fleischhacker, Piotr Warczok, Ahmad Falahati, and Ernst Kozeschnik. 2020. "Characterisation of a High-Performance Al–Zn–Mg–Cu Alloy Designed for Wire Arc Additive Manufacturing" Materials 13, no. 7: 1610. https://doi.org/10.3390/ma13071610

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