Microstructure and Properties of ZL114A Alloy Repaired by Wire Arc Additive Repair

BIN Haoyu; LIANG Jie; LI Ran; WANG Haoming; ZHANG Hongkai; FANG Xuewei; HUANG Ke

doi:10.3969/j.issn.1674-6457.2025.08.017

PDF(6661 KB)

Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (8) : 161-168. DOI: 10.3969/j.issn.1674-6457.2025.08.017

Additive Manufacturing

Microstructure and Properties of ZL114A Alloy Repaired by Wire Arc Additive Repair

BIN Haoyu¹, LIANG Jie², LI Ran¹, WANG Haoming³, ZHANG Hongkai³, FANG Xuewei³, HUANG Ke^3,*

Author information +

History +

Abstract

The work aims to explore the effects of the wire arc additive process and heat treatment system on the ZL114A repair parts, so as to provide a reference for the subsequent on-site repair. Wire arc additive technology was used to repair the cast T6 temper aluminum alloy ZL114A. The effects of different arc modes on the repaired interface were compared, and the microstructure and mechanical properties of the repaired area were analyzed. The results showed that good metallurgical bonding could be achieved by repairing with the CMT-P arc mode, and aggregation of eutectic silicon existed in the repaired interface. Eutectic silicon in the additive repair region showed a continuous sheet-like distribution. The microhardness in the repaired area was significantly lower than that of the T6 tempered substrate, and there was a heat affected zone with approximately 0.5 mm at the interface. The performance of the repaired part could be significantly improved by the overall heat treatment. The heat affected zone of the substrate disappeared. The tensile strength and elongation of the repaired part were improved compared with those before heat treatment, which reach 338 MPa and 5.6% respectively. Compared with those before heat treatment, both the tensile strength and the elongation of the repaired parts increase after heat treatment, and the mechanical properties of the repaired samples reach the HB962 standard.

Key words

ZL114A / wire arc additive repair / microstructure / mechanical properties

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

BIN Haoyu, LIANG Jie, LI Ran, WANG Haoming, ZHANG Hongkai, FANG Xuewei, HUANG Ke. Microstructure and Properties of ZL114A Alloy Repaired by Wire Arc Additive Repair[J]. Journal of Netshape Forming Engineering. 2025, 17(8): 161-168 https://doi.org/10.3969/j.issn.1674-6457.2025.08.017

References

[1] ZHANG J L, SONG B, WEI Q S, et al.A Review of Selective Laser Melting of Aluminum Alloys: Processing, Microstructure, Property and Developing Trends[J]. Journal of Materials Science & Technology, 2019, 35(2): 270-284.
[2] HE F Y, YUAN L, MU H C, et al.Research and Application of Artificial Intelligence Techniques for Wire Arc Additive Manufacturing: A State-of-the-Art Review[J]. Robotics and Computer-Integrated Manufacturing, 2023, 82: 102525.
[3] DAI W, GUO W, XIAO J, et al.Tailoring Properties of Directed Energy Deposited Al-Mg Alloy by Balancing Laser Shock Peening and Heat Treatment[J]. Journal of Materials Science & Technology, 2024, 203: 78-96.
[4] ZHOU Y, CHANG T X, FANG X W, et al.Tailoring the Mechanical Properties and Thermal Stability of Additive Manufactured Micro-Alloyed Al-Cu Alloy via Multi- Stage Heat Treatment[J]. Materials & Design, 2023, 233: 112287.
[5] YI H, YANG L, JIA L, et al.Porosity in Wire-Arc Directed Energy Deposition of Aluminum Alloys: Formation Mechanisms, Influencing Factors and Inhibition Strategies[J]. Additive Manufacturing, 2024, 84: 104108.
[6] 张森棠. 航空发动机难加工材料关键数控技术及装备[J]. 航空制造技术, 2009, 52(5): 46-49.
ZHANG S T.Key NC Technologies and Equipment for Difficult-to-Machine Materials of Aeroengine[J]. Aeronautical Manufacturing Technology, 2009, 52(5): 46-49.
[7] 葛宁. 涡轴发动机发展与技术趋势[J]. 南京航空航天大学学报, 2018, 50(2): 145-156.
GE N.Development and Technical Trend of Turbo Shaft Engine[J]. Journal of Nanjing University of Aeronautics & Astronautics, 2018, 50(2): 145-156.
[8] FANG X W, LI H, LI X G, et al.Effect of Post Heat Treatment on the Microstructure and Mechanical Properties of Wire-Arc Additively Manufactured A357 Alloy Components[J]. Materials Letters, 2020, 269: 127674.
[9] SUN X J, ZENG C Y, CONG B Q, et al.Microstructure and Mechanical Property of A356 Cast Remanufactured by Ultrasonic Frequency Pulsed TIG Process[J]. Materials Letters, 2024, 357: 135766.
[10] 周永江, 熊艳才, 洪润洲, 等. ZL114A合金疲劳行为研究[J]. 航空材料学报, 2007, 27(4): 10-13.
ZHOU Y J, XIONG Y C, HONG R Z, et al.Study on Fatigue Behaviors of ZL114A Alloy[J]. Journal of Aeronautical Materials, 2007, 27(4): 10-13.
[11] 张永泽. 激光增减材修复铝合金机匣技术研究[D]. 沈阳: 沈阳航空航天大学, 2019.
ZHANG Y Z.Study on the Technology of Laser Additive and Subtractive Repairing Aluminium Alloy Casing[D]. Shenyang: Shenyang Aerospace University, 2019.
[12] 张鑫. 2A12铝合金CMT增材修复件组织及性能研究[D]. 南昌: 南昌航空大学, 2022.
ZHANG X.Study on Microstructure and Properties of CMT Additive Repair of 2A12 Aluminum Alloy[D]. Nanchang: Nanchang Hangkong University, 2022.
[13] ZHAO J, YANG Y R, KOBIR M H, et al.Driving Additive Manufacturing towards Circular Economy: State-of- the-Art and Future Research Directions[J]. Journal of Manufacturing Processes, 2024, 124: 621-637.
[14] ZHOU Y, FANG X W, XI N Y, et al.Enhanced Strength and Ductility of Laser-Directed Energy Deposition Repaired IN718 Superalloy via a Novel Tailored Heat Treatment[J]. Journal of Materials Science & Technology, 2024, 199: 86-101.
[15] MONTANARI R, PALOMBI A, RICHETTA M, et al.Additive Manufacturing of Aluminum Alloys for Aeronautic Applications: Advantages and Problems[J]. Metals, 2023, 13(4): 716.
[16] JIAO G H, FANG X W, ZHANG M G, et al.Synergistic Improvement of Mechanical Property and Thermal Expansion of Wire-Arc DED Invar Alloy Enabled by a Novel Deposition Strategy[J]. Journal of Manufacturing Processes, 2024, 121: 121-135.
[17] 张帅锋, 吕逸帆, 魏正英, 等. 基于CMT的电弧熔丝增材Ti-6Al-3Nb-2Zr-1Mo合金的组织与性能[J]. 焊接学报, 2021, 42(2): 56-62.
ZHANG S F, LYU Y F, WEI Z Y, et al.Microstructures and Mechanical Properties of Ti-6Al-3Nb-2Zr-1Mo Alloy Fabricated by CMT-Wire Arc Additive Manufacturing[J]. Transactions of the China Welding Institution, 2021, 42(2): 56-62.
[18] 周祥曼, 田启华, 杜义贤, 等. 外加横向磁场作用电弧增材成形过程中的传热传质仿真[J]. 机械工程学报, 2018, 54(12): 193-206.
ZHOU X M, TIAN Q H, DU Y X, et al.Simulation of Heat and Mass Transfer in Arc Welding Based Additive Forming Process with External Transverse Magnetic Field[J]. Journal of Mechanical Engineering, 2018, 54(12): 193-206.
[19] JIAO G H, FANG X W, LI X Z, et al.High Performance Ultrasonic Vibration Assisted Wire-Arc Directed Energy Deposition of Invar Alloy[J]. Journal of Materials Processing Technology, 2024, 332: 118534.
[20] 邹文凤, 戴开明, 曲飞飞. 铝合金增材制造工艺研究现状[J]. 精密成形工程, 2024, 16(9): 143-152.
ZOU W F, DAI K M, QU F F.Research Status of Aluminum Alloy Additive Manufacturing[J]. Journal of Netshape Forming Engineering, 2024, 16(9): 143-152.
[21] HONG X Y, XIAO G Q, ZHANG Y C, et al.Research on Gradient Additive Remanufacturing of Ultra-Large Hot Forging Die Based on Automatic Wire Arc Additive Manufacturing Technology[J]. The International Journal of Advanced Manufacturing Technology, 2021, 116(7): 2243-2254.
[22] LI X L, HAN Q L, ZHANG G J.Large-Size Sprocket Repairing Based on Robotic GMAW Additive Manufacturing[J]. Welding in the World, 2021, 65(5): 793-805.
[23] 申发明, 崔岩峰, 邵童阁, 等. 激光沉积修复铸造铝合金ZL114A变形与性能调控[J]. 焊接学报, 2024, 45(8): 121-128.
SHEN F M, CUI Y F, SHAO T G, et al.Tailored Deformation and Properties of Cast Aluminum Alloy ZL114A Repaired by Laser Deposition[J]. Transactions of the China Welding Institution, 2024, 45(8): 121-128.
[24] 张震. 热处理与补焊工艺对ZL114A机匣组织性能影响研究[D]. 哈尔滨: 哈尔滨工业大学, 2021.
ZHANG Z.Effect of Heat Treatment and Repair Welding Process on Microstructure and Properties of ZL114A Gearbox[D]. Harbin: Harbin Institute of Technology, 2021.
[25] 刘文慧, 李天文, 梁春霞, 等. 补焊对铝合金砂型铸件性能的影响[J]. 特种铸造及有色合金, 2018, 38(1): 93-96.
LIU W H, LI T W, LIANG C X, et al.Effects of Welding Repair on Performance of Sand Mmold Casting Aluminum Alloy Castings[J]. Special Casting & Nonferrous Alloys, 2018, 38(1): 93-96.
[26] 李承德, 顾惠敏, 王伟, 等. 电弧增材制造ZL114A铝合金的组织与性能[J]. 稀有金属材料与工程, 2019, 48(9): 2917-2922.
LI C D, GU H M, WANG W, et al.Microstructure and Properties of ZL114A Aluminum Alloy Prepared by Wire Arc Additive Manufacturing[J]. Rare Metal Materials and Engineering, 2019, 48(9): 2917-2922.
[27] CHANG T X, FANG X W, LIU G, et al.Wire and Arc Additive Manufacturing of Dissimilar 2319 and 5B06 Aluminum Alloys[J]. Journal of Materials Science & Technology, 2022, 124: 65-75.
[28] LI X Z, FANG X W, ZHANG M G, et al.Enhanced Strength-Ductility Synergy of Magnesium Alloy Fabricated by Ultrasound Assisted Directed Energy Deposition[J]. Journal of Materials Science & Technology, 2024, 178: 247-261.
[29] CHANG T X, FANG X W, ZHOU Y, et al.Heterogeneous Interfaces of Aluminum Bronze/Inconel 718 Dissimilar Alloys under Different Wire Arc Directed Energy Deposition Sequences[J]. International Journal of Extreme Manufacturing, 2025, 7(1): 015003.
[30] KOU S.Welding Metallurgy[M]. Hoboken: John Wiley & Sons Inc, 2003.