Forming Quality and Microstructure Properties of 6201 Aluminum Alloy Fabricated by CMT+P Arc Additive Manufacturing

CHEN Qi; LIU Yan; WANG Zemin; MOSE Muga; LI Xiaofei; WANG Liangyu; CHEN Jialong

doi:10.3969/j.issn.1674-6457.2026.06.015

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (6) : 171-180. DOI: 10.3969/j.issn.1674-6457.2026.06.015

Additive Manufacturing

Forming Quality and Microstructure Properties of 6201 Aluminum Alloy Fabricated by CMT+P Arc Additive Manufacturing

CHEN Qi^a, LIU Yan^b*, WANG Zemin^a, MOSE Muga^a, LI Xiaofei^a, WANG Liangyu^a, CHEN Jialong^a

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Abstract

To address the application requirements of 6201 aluminum alloy in aerospace and automotive manufacturing, the work aims to optimize the CMT+P arc additive manufacturing process parameters and investigate the relationship between microstructure and mechanical properties, providing tailored process parameters for additive manufacturing components. With CMT+P technology, the effects of welding current and speed on the forming quality, mechanical properties, and microstructure of 6201 aluminum alloy components were investigated through low heat input and pulsed droplet transition modes. Within the welding current range of 75-150 A, the maximum accumulation width, effective accumulation width, and tensile strength range for single-layer multi-wall structures were 3.08 mm, 3.33 mm, and 9.03 MPa, respectively. Within the welding speed range of 450-600 mm/min, the corresponding values were 0.57 mm, 0.99 mm, and 12.45 MPa. The optimal process parameters for both single-pass single-layer and multi-layer wall structures were 100 A welding current and 500 mm/min welding speed. At these parameters, the multi-layer wall structure achieved a maximum tensile strength of 166.33 MPa, with a ductile fracture showing dimples and minor porosity. The microstructure exhibited a coexistence of equiaxed and columnar crystals, with grain size, morphology, and distribution being relatively uniform. The welding current and welding speed significantly affect the forming quality and organizational mechanical properties of CMT+P additive manufacturing 6201 aluminum alloy. The optimal process parameters can achieve synergistic optimization of forming and performance of additive components, providing process support for the engineering application of 6201 aluminum alloy additive components.

Key words

6201 aluminum alloy / CMT+P additive manufacturing / forming quality / tensile properties / microstructure

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CHEN Qi, LIU Yan, WANG Zemin, MOSE Muga, LI Xiaofei, WANG Liangyu, CHEN Jialong. Forming Quality and Microstructure Properties of 6201 Aluminum Alloy Fabricated by CMT+P Arc Additive Manufacturing[J]. Journal of Netshape Forming Engineering. 2026, 18(6): 171-180 https://doi.org/10.3969/j.issn.1674-6457.2026.06.015

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Funding

Natural Science Foundation of Liaoning Province, China (2023-MS-320); National Undergraduate Innovation and Entrepreneurship Training Program of Shenyang University (S202511035059)