Wire and arc additive manufacturing of 4043 Al alloy using a cold metal transfer method

Cold metal transfer plus pulse(C+P)arc was applied in the additive manufacturing of 4043 Al alloy parts.Parameters in the manufacturing of the parts were investigated.The properties and microstructure of the parts were also characterized.Experimental results showed that welding at a speed of 8 mm/s and a wire feeding speed of 4.0 m/min was suitable to manufacture thin-walled parts,and the reciprocating scanning method could be adopted to manufacture thick-walled parts.The thin-walled parts of the C+P mode had fewer pores than those of the cold metal transfer(CMT)mode.The thin-and thick-walled parts of the C+P mode showed maximum tensile strengths of 172 and 178 MPa,respectively.Hardness decreased at the interface and in the coarse dendrite and increased in the refined grain area.

Study on Relationship Between Arc Behavior and Joint Forming in Cold Metal Transfer Welding Technology with Polarity⁃Exchanging

Cold metal transfer with polarity⁃exchanging is a new integrated welding technology based on MIG.Due to the alternation of the positive and negative polarities of the wire,favorable control upon the deposition rate and the welding shape coefficient was obtained in order to meet the desired joint design,and the related controlling principles and joint characteristics were reported.Droplet transfer physical behavior exhibited strong dependability on the studied welding parameters,such as welding voltage,welding current,wire feeding speed,and polarity⁃exchanging.This welding technology provides a new way for the welding of body⁃in⁃white(BIW)thin sheet with special demands.Moreover,the typical quality defects of MIG were greatly improved.Our study provides important technical information from the perspective of industrial application of MIG and sheds light on the higher application level of MIG in BIW welding.

Microstructure and mechanical properties of dissimilar joint between aluminum and aluminum-coated steel by cold metal transfer process

Two dissimilar materials, aluminum alloy and aluminum-coated steel, were joined by cold metal transfer process using AlSi5 filler wire. To this end, the steel was coated with Al-Si. The steel did not melt and aluminum was melt to form the joint during the process, it was actually cold metal transfer welding-brazing. The macrostructure, microstructure, alloy element distribution, and inter-metallic compounds were analyzed by optical microscopy, scanning electron microscopy, and energy dispersive spectroscopy. It was found that the Al-Si coating dissolved into the weld metal. The pre-existing thin Fe-Al- Si ternary inter-metallic compounds in the interface between the Ak-Si coating layer and base metal steel also partially dissolved into the weld zone, tending to reduce the thickness of inter-metallic compounds. Approximate 3 μm thick undissolved intermetallic compound was found at the interface after welding which could guarantee sound bonding strength in dissimilar materials joining. The sample was fractured at the fusion zone near the aluminum side in the tensile test. The ultimate tensile strength was about 156 MPa, and the fracture mode is ductile failure in nature according to its morphology.

Microstructure characteristics and mechanical properties of steel stud to Al alloy by CMT welding-brazing process

Cold metal transfer （CMT） welding of nickel-coated Q235 steel studs with 606l Al alloy was carried out using ER4043 as filler metal. The welding process was stable, and appearance of weld formed well without surface defect under the parameters of welding current 121 A, welding voltage 15.4 V and welding speed 6 r/min. The microstructure of fiUer metal was analyzed by means of scanning electron microscopy. The filler metal and 6061 Al alloy were fused to form fusion welding interface, the fusion zone had a good bonding without any micro defect. The steel stud did not melt and brazing interface was formed between the filler metal and steel stud. Two different reaction layers existed in the brazing interface, the Fe2Al5 layer about 10 -12 p^m formed near the steel stud side, and the other layer was mainly composed of FeAl3. Nickel-rich zone was formed in the root toe area of the fillet weld, which was mainly composed of Al3Ni2. The tensile tests showed that the maximum shearing strength of the joints was 129 MPa. The joint was brittle fractured in the intermetallic compound layer where plenty of FeAl3 were distributed continuously.

Microstructure and Properties of an Al 6061/Galvanized Plate Fabricated by CMT Welding

Aluminum alloy 6061 was welded with zinc coated low carbon steel by cold metal transfer (CMT).The microstructure composition,morphology and growth process of the welding joint and the HAZ were researched.The weld area on the side of the galvanized steel sheet mainly contains Fe2Al5.And on the side of the aluminum alloy substrate,it is mainly filled with a needle-like FeAl3.At the same time,Al8Fe2Si is formed at the edge of FeAl3.The zinc-rich region on the side of the aluminum alloy mainly contains an aluminum-zinc solid solution and an aluminum-zinc co-crystal,and the current size had no significant effect on the type and morphology of the compounds produced in the interface layer.

Fronius TPS/i焊接系统的先进工艺及其应用

简要阐述了Fronius伏能士TPS/i智能焊接平台中几种先进的焊接工艺,同时介绍了几种工艺的焊接应用,为客户的实际应用提供参考与借鉴。

High-Superelasticity NiTi Shape Memory Alloy by Directed Energy Deposition-Arc and Solution Heat Treatment

Directed energy deposition-arc(DED-Arc)technology has the advantages of simple equipment,low manufacturing cost and high deposition rate,while the use of DED-Arc has problems of microstructure inhomogeneity,position dependence of macroscopic mechanical properties and anisotropy.Therefore,it is necessary to carry out a subsequent heat treatment to improve its microstructure uniformity,mechanical properties and superelasticity.In this investigation,the DED-Arc 15-layer NiTi alloy thin-walled parts with the solution treatment at different process parameters were studied to analyze the effects of solution heat treatment on microstructure,phase composition,phase transformation,microhardness,tensile and superelasticity.The temperature range of solution treatment is 800-1050℃,and the treatment time range is 1-5.5 h.The results show that after solution treatment at 800℃/1 h,the content of precipitated phase decreases,the grain is refined,the microhardness increases,and the mechanical properties in the 0°direction are improved.The strain recovery rate after 10 tensile cycles has increased from 37.13%(as-built)to 49.25%(solid solution treatment).This research provides an effective post treatment method for high-performance DED-Arc NiTi shape memory alloys.