Influência do modo de corrente CC e CA na fabricação de componentes de alumínio pelo método de manufatura aditiva WAAM

Abstract

Additive manufacturing, combined with Industry 4.0 concepts, has revolutionized production processes, providing greater customization and efficiency in the manufacture of parts. However, there are still gaps in the definition of the ideal parameters for aluminum deposition by the electric arc additive manufacturing process. In this context, this research seeks to evaluate the influence of the deposition current mode on the manufacture of aluminum components by the WAAM additive manufacturing method, analyzing their mechanical properties and microstructure. To this end, experimental tests are conducted on Al5356 samples, using direct and alternating current, with the support of the DOE methodology for defining the parameters. The mechanical properties are evaluated through tensile tests, Vickers microhardness, Charpy impact, and microscopic analyses. The research results show that for alternating current, the optimized deposition parameters based on DOE are Tb 4.4 ms, In 47 A, Tn 2.4 ms, Va 6.0 m/min, Vs 39.6 cm/min, Ip 457.3 A, Ib 60 A and Tp 4.6 ms and for direct current, they are Vs 20 mm/s, Va 6 m/min and voltage 24 V. Metallography revealed more distinct interfaces between beads for the AC samples. Vickers microhardness tests showed maximum values of 75.17 HV for DC and 74.80 HV for AC. The tensile test results showed that for AC, the maximum tensile strength was 249.13 MPa in the horizontal direction and presented lower ductility, while for DC, the maximum value was 244.84 MPa in the vertical direction and higher ductility with an elongation of 34.90%. The Charpy impact test showed that the samples deposited with alternating current had greater toughness, with values of 30 J and 31.33 J in the horizontal and vertical directions, when compared to those deposited by direct current. Fractography analyses for the tensile and impact tests revealed high porosity for AC deposits and a greater amount of microporosity for DC deposits.