Process development for wire-based laser metal deposition of 5087 aluminium alloy by using fibre laser

• Published in: Journal of manufacturing processes 2018-08, Vol.34, p.721-732
• Main Authors: Froend, M., Riekehr, S., Kashaev, N., Klusemann, B., Enz, J.
• Format: Article
• Language: English
• Subjects: Aluminium alloy; Laser additive manufacturing; Laser metal deposition; Microstructure; Pre-heating; Tailored geometrical shape
• ISSN: 1526-6125; 2212-4616
• DOI: 10.1016/j.jmapro.2018.06.033

•Laser metal deposition process for the Al-Mg-alloy EN AW-5087 is conducted.•Parameter windows achieving defect-free structures were identified.•Possible mechanisms of defect formations as well as first microstructural examinations were conducted.•Tailoring of the geometrical shape of the deposited material by specific parameter adjustments is enabled. In recent decades, laser metal deposition, as a part of additive manufacturing, developed into a promising methodology in industrial fields. In recent years, there has been an increased interest in the processability of lightweight high-strength structural materials, such as aluminium alloys. However, in terms of wire-based laser metal deposition, there is still a lack of knowledge with regard to the processability of aluminium alloys. In this research, the process development for wire-based laser metal deposition of a 5087 aluminium alloy (AlMg4.5 MnZr) has been conducted. It is observed that pre-heating is beneficial in terms of porosity and distortion reduction. Within optimized parameter ranges, it is possible to control the geometric shape, dilution, and aspect ratios of the deposited layers in a systematic way. Accordingly, defect-free layers with tailored geometrical features can be processed and adapted to specific process requirements.