Effect of Interlayer FSP on the Temperature and Stress Fields of WAAM Al Alloy

LIU Li; XU Wanghui; LIU Ruizhe; XU Hu; HUANG Yongxian; DONG Chunlin

doi:10.3969/j.issn.1674-6457.2025.06.019

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (6) : 177-186. DOI: 10.3969/j.issn.1674-6457.2025.06.019

Light Alloy Forming

Effect of Interlayer FSP on the Temperature and Stress Fields of WAAM Al Alloy

LIU Li¹, XU Wanghui¹, LIU Ruizhe¹, XU Hu¹, HUANG Yongxian², DONG Chunlin^1*

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Abstract

Specific to the common problems such as many defects, coarse grains and low mechanical properties in aluminum alloy by arc additive manufacturing, the work aims to adopt a new technology of wire arc addictive manufacturing (WAAM) and friction stir processing (FSP) to study the effect of interlayer FSP on the temperature and stress fields of WAAM Al alloy. By establishing a thermo-mechanical coupling model of WAAM-FSP hybrid AM method, the temperature and stress fields during WAAM and WAAM-FSP process were studied for comparison, and the effect of interlayer FSP on the temperature and stress fields of WAAM aluminum alloy was analyzed. The maximum temperature of 2319 aluminum alloy during WAAM process reached 1 575 ℃. During deposition of the next layer, the peak temperature of the previous additive layer exceeded the liquidus line of the 2319 aluminum alloy, causing the additive layer to partially remelt. The peak temperature of the additive specimen increased from 1 575 ℃ to 1 619 ℃ by the interlayer FSP. In addition, the temperature of the firstly deposited layer reached around 395 ℃ after interlayer FSP. The effect of subsequent WAAM process and interlayer FSP on the temperature rise of the additive layers decreased with the increase of the number of layers. Secondly, by introducing interlayer FSP, the stress concentration area between the deposited layers and the substrate was reduced, and the peak stress in the deposited layer was reduced by about 20 MPa. The interlayer FSP can decrease the cooling rate and temperature gradient of aluminum alloy produced by WAAM. At the same time, the thermal-mechanical coupling in the process of interlayer FSP makes the stress distribution in the additive more uniform, which solves the problem of stress concentration in the additive.

Key words

Al alloy / WAAM-FSP hybrid additive manufacturing / numerical simulation / temperature field / stress field

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LIU Li, XU Wanghui, LIU Ruizhe, XU Hu, HUANG Yongxian, DONG Chunlin. Effect of Interlayer FSP on the Temperature and Stress Fields of WAAM Al Alloy[J]. Journal of Netshape Forming Engineering. 2025, 17(6): 177-186 https://doi.org/10.3969/j.issn.1674-6457.2025.06.019

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Funding

National Natural Science Foundation of China (52205341); Guangdong Basic and Applied Basic Research Foundation (2021A1515110062); State Key Laboratory of Precision Welding & Joining of Materials and Structures (MSWJ-24Z05); The International Science and Technology project of Guangzhou Development District (2023GH19)