Effect of Wire Arc Additive Manufacturing Process Parameters on Bead Geometry and Porosity Formation of 5356 Aluminum alloy

Abstract

Wire Arc Additive Manufacturing holds significant promise for producing large, intricate aluminum parts with reduced cost and material waste. This study aims to investigate the influence of process parameters on the porosity formation and bead geometry of aluminum alloy ER5356, including voltage, scanning speed, and energy density. A series of 36 single-track aluminum samples were fabricated under varying welding conditions. The results show that increasing voltage enhances bead width and penetration but reduces height and contact angle. Similarly, higher scanning speeds result in smaller bead dimensions. Energy density influenced both bead geometry and porosity, with higher energy densities increasing porosity. The investigation revealed that the most effective voltage range for achieving consistent track formation is between 22 and 24 V. In addition, it was found that higher scanning speeds and lower energy densities reduced porosity. These insights are crucial for refining Wire Arc Additive Manufacturing parameters for aluminum alloys, decreasing defects, and improving material performance for industrial uses.