Microstructure and Properties of Forging-arc Additive Hybrid Manufactured 7xxx Series Aluminum Alloys after Heat Treatment

WEI Wenyi

doi:10.3969/j.issn.1674-6457.2026.03.004

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (3) : 36-45. DOI: 10.3969/j.issn.1674-6457.2026.03.004

Light Alloy Forming

Microstructure and Properties of Forging-arc Additive Hybrid Manufactured 7xxx Series Aluminum Alloys after Heat Treatment

WEI Wenyi^*

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Abstract

To achieve rapid manufacturing of large-scale structures, leveraging the respective advantages of forging and additive manufacturing (AM), the work aims to propose a forging-wire arc hybrid manufacturing (FAHM) method for 7xxx series aluminum alloys and elucidate the effect mechanism of heat treatment on the microstructure and properties of hybrid manufactured specimens. TIG-wire arc additive manufacturing (WAAM) was employed to fabricate FAHM specimens of 7xxx series aluminum alloys. Through various material characterization techniques, including scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD), the effect mechanism of T6 heat treatment on the microstructure and properties of the hybrid specimens was investigated. The interface exhibited sound metallurgical bonding, with defects meeting the Class I requirements of radiographic inspection standards. The forging zone consisted of fine equiaxed grains and the grain size was 15.20 μm. Within the heat-affected zone (HAZ), grain coarsening was observed while equiaxed grains remained predominant and the grain size was 23.40 μm. The as-deposited WAAM zone featured coarse equiaxed grains and the grain size was 42.30 μm. Following T6 heat treatment, η-phase precipitates dissolved and diffused into the aluminum substrate, forming finely dispersed η' strengthening phases. The hybrid specimens demonstrated excellent mechanical properties, with tensile strength exceeding 500 MPa and elongation exceeding 10%. However, the strength of the WAAM zone, constrained by its coarse-grained structure, remained lower than that of the forged substrate. Consequently, tensile fracture consistently occurred within the WAAM. The FAHM approach for high-strength aluminum alloys yields superior microstructures and mechanical properties. This work provides a theoretical foundation for the rapid manufacturing of critical high-strength aluminum alloy structures, such as aircraft frame beams.

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forging-additive hybrid manufacturing / 7xxx aluminum alloy / solution aging treatment / microstructure transition / mechanical properties

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WEI Wenyi. Microstructure and Properties of Forging-arc Additive Hybrid Manufactured 7xxx Series Aluminum Alloys after Heat Treatment[J]. Journal of Netshape Forming Engineering. 2026, 18(3): 36-45 https://doi.org/10.3969/j.issn.1674-6457.2026.03.004

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