{"title":"Study on Mechanical, Microstructural and Corrosion Analysis of Wire Arc Additive Manufactured AZ31 Magnesium Alloy","authors":"Suresh Goka, M. Manjaiah, M. Joseph Davidson","doi":"10.1007/s12540-024-01864-w","DOIUrl":null,"url":null,"abstract":"<div><p>Wire arc additive manufacturing (WAAM) offers significant potential for producing large-scale magnesium (Mg) alloy components, which are highly valuable for industries such as automotive and aerospace. This study explores the microstructure, mechanical properties, and corrosion performance of AZ31 magnesium alloy produced using the cold metal transfer (CMT)-WAAM process. Microstructural analysis reveals that the WAAM-fabricated AZ31 exhibits an equiaxed grain structure with intergranular precipitates, influenced by welding parameters and cooling rates. The study also examines the impact of process parameters on bead geometry and microstructure, emphasizing the relationship between wire feed rate, travel speed, and bead characteristics. Tensile samples were extracted from the base plate at orientations of 0°, 45°, and 90°. The average ultimate tensile strength (UTS) and percentage elongation for the WAAM-processed AZ31 magnesium alloy ranged from 289 to 301 MPa and 19 to 22%, respectively, depending on the orientation. WAAM-fabricated AZ31 which is superior compared to conventional cast and wrought alloys, attributed to fine grain structure and evenly distribution of precipitates such as α-Mg and Mg<sub>17</sub>Al<sub>12</sub>. X-ray diffraction analysis and EDS validate the presence of α-Mg, and Mg<sub>17</sub>Al<sub>12</sub> phases in the fabricated alloy. Corrosion tests revealed that the formation of a protective film significantly enhanced the corrosion resistance of WAAM-fabricated samples compared to the wrought alloy. Electrochemical testing showed superior corrosion resistance in the bottom region of the thin wall, with a corrosion rate of approximately 12 mm/y, compared to the top region, which had a corrosion rate of about 16 mm/y. This improved performance was attributed to the refined grain structure and the presence of a protective oxide film.</p><h3>Graphical Abstract</h3><div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":703,"journal":{"name":"Metals and Materials International","volume":"31 7","pages":"2104 - 2122"},"PeriodicalIF":4.0000,"publicationDate":"2024-12-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Metals and Materials International","FirstCategoryId":"88","ListUrlMain":"https://link.springer.com/article/10.1007/s12540-024-01864-w","RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q2","JCRName":"MATERIALS SCIENCE, MULTIDISCIPLINARY","Score":null,"Total":0}
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Abstract
Wire arc additive manufacturing (WAAM) offers significant potential for producing large-scale magnesium (Mg) alloy components, which are highly valuable for industries such as automotive and aerospace. This study explores the microstructure, mechanical properties, and corrosion performance of AZ31 magnesium alloy produced using the cold metal transfer (CMT)-WAAM process. Microstructural analysis reveals that the WAAM-fabricated AZ31 exhibits an equiaxed grain structure with intergranular precipitates, influenced by welding parameters and cooling rates. The study also examines the impact of process parameters on bead geometry and microstructure, emphasizing the relationship between wire feed rate, travel speed, and bead characteristics. Tensile samples were extracted from the base plate at orientations of 0°, 45°, and 90°. The average ultimate tensile strength (UTS) and percentage elongation for the WAAM-processed AZ31 magnesium alloy ranged from 289 to 301 MPa and 19 to 22%, respectively, depending on the orientation. WAAM-fabricated AZ31 which is superior compared to conventional cast and wrought alloys, attributed to fine grain structure and evenly distribution of precipitates such as α-Mg and Mg17Al12. X-ray diffraction analysis and EDS validate the presence of α-Mg, and Mg17Al12 phases in the fabricated alloy. Corrosion tests revealed that the formation of a protective film significantly enhanced the corrosion resistance of WAAM-fabricated samples compared to the wrought alloy. Electrochemical testing showed superior corrosion resistance in the bottom region of the thin wall, with a corrosion rate of approximately 12 mm/y, compared to the top region, which had a corrosion rate of about 16 mm/y. This improved performance was attributed to the refined grain structure and the presence of a protective oxide film.
期刊介绍：
Metals and Materials International publishes original papers and occasional critical reviews on all aspects of research and technology in materials engineering: physical metallurgy, materials science, and processing of metals and other materials. Emphasis is placed on those aspects of the science of materials that are concerned with the relationships among the processing, structure and properties (mechanical, chemical, electrical, electrochemical, magnetic and optical) of materials. Aspects of processing include the melting, casting, and fabrication with the thermodynamics, kinetics and modeling.
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