Microstructural analysis and preliminary wear assessment of wire arc additive manufactured AA 5083 aluminum alloy for lightweight structures

The proliferation of Wire Arc Additive Manufacturing (WAAM) has significantly enhanced the production capabilities for lightweight and structurally robust components. This study investigates the microstructural characteristics, tensile properties, and preliminary wear performance of AA 5083 aluminum alloy processed via WAAM, focusing on applications for lightweight structures. Using SEM and XRD, microstructural changes during the WAAM process are analyzed, and tensile testing evaluates the mechanical properties, including ultimate tensile strength (UTS) and elongation. The results reveal that the microstructure consists of α-Al and β-(Al₅Mg₈) phases, with the Al₅Mg₈ phase distributed along grain boundaries and within grains. Notably, the grain size in the Y-direction (building direction) is larger than in the X-direction (deposition direction) due to temperature variations during processing. Tensile testing shows that horizontal samples (X-direction) have a UTS of 295 ± 5 MPa and elongation of 20.08 ± 0.8 %, while vertical samples (Y-direction) have a UTS of 267 ± 10 MPa and elongation of 16.43 ± 2.1 %. This results in an anisotropy of 9.4 % in tensile strength, reflecting the differences in mechanical properties between the two directions. The WAAM AA 5083 aluminum part exhibits a maximum wear rate of 5.22 × 10⁻³ mm³/m and a coefficient of friction of 0.52 at a load of 3.5 kg and 450 rpm. Under these conditions, deep grooves, layer separation, and load-induced deformation are observed. The primary wear mechanisms include delamination, adhesion, and abrasion. Hardness levels are consistent in the X-direction and show minimal variance in the Y-direction, with an average hardness of 89.4 ± 5.14 HV0.5. The study demonstrates that WAAM-produced AA 5083 aluminum alloy, with an anisotropy below 10 %, is suitable for real-time lightweight structures, offering effective performance in engineering applications such as aerospace and automotive industries. Future research should focus on further quantifying wear behavior and optimizing processing conditions to enhance material performance for specific applications.