Effect of fast frequency double pulse current on microstructural characteristics and mechanical properties of wire arc additively manufactured Ti-6Al-4V alloy

• Published in: Journal of manufacturing processes 2024-12, Vol.131, p.52-72
• Main Authors: Kuang, Yingwei, Hu, Jianliang, Liao, Haipeng, Zhu, Zeguang, Su, Weiji, Du, Wenting, Zhang, Qin, Wang, Zhenmin
• Format: Article
• Language: English
• Subjects: Fast-frequency double pulse current; Mechanical properties; Microstructure; Variant selection; Wire arc additive manufacturing
• ISSN: 1526-6125
• DOI: 10.1016/j.jmapro.2024.09.023

This study introduces an innovative technique known as fast-frequency double pulse wire arc metal additive manufacturing (FFDP-WAAM). This method employs periodic fluctuations in arc plasma and force to enhance the stirring effect within the molten pool, resulting in the fragmentation of β grains and the formation of finer prior-β grains. The microstructure primarily comprises α', attributed to the high cooling rates and minimal heat accumulation. Compared to the conventional gas tungsten arc welding-based WAAM (CGT-WAAM) process, FFDP-WAAM significantly reduces α-variant selection, thereby achieving a more uniform α phase orientation distribution. Additionally, ultrasonic vibration in the FFDP-WAAM process facilitates recrystallization and mitigates residual strain. The tensile strength and elongation of the FFDP-WAAM specimens reached 939.2 MPa and 9.0 %, respectively, whereas the CGT-WAAM specimens showed a lower tensile strength of 830 MPa and elongation of 9.2 %. The enhanced strength, fatigue life and microhardness of Ti-6Al-4V produced by FFDP-WAAM is ascribed to the refined grain-size distribution. Furthermore, the low Schmid factor (SF) distribution and the stable triangular structure of Category I α-clusters are anticipated to contribute to the increased strength of the FFDP-WAAM-fabricated wall.