Microstructure and Properties of 5356 Aluminum Alloy by Additive and Subtractive Hybrid Manufacturing

doi:10.3901/JME.2025.24.118

Abstract

Abstract: In recent years, in the face of the urgent need to improve the surface accuracy of complex components in additive manufacturing, a hybrid manufacturing technology combining additive manufacturing and subtractive manufacturing in the same equipment is proposed. In this paper, the thin-walled sample of 5356 aluminum alloy is prepared by the hybrid manufacturing method of wire arc additive manufacturing and subtractive manufacturing. The microstructure and static and dynamic mechanical properties are tested and analyzed, and compared with the wire arc additive manufacturing method. The results show that the microstructures of the two are α phase (Al) matrix and β phase (Al₃Mg₂) precipitated at the grain boundary, which are composed of fine columnar grains and equiaxed grains. The grain sizes are 71.81 μm and 62.05 μm, respectively. The quasi-static mechanical properties of the two are equivalent, and the direction perpendicular to the deposition direction (horizontal) is better than the direction parallel to the deposition direction (vertical). With the increase of strain rate, the yield stress and flow stress increase continuously, showing obvious strain rate strengthening effect, and the horizontal direction also exhibits better dynamic mechanical properties than the vertical. When the strain rate is 3 800 s^-1, the yield stress and flow stress in the horizontal direction under the additive subtractive hybrid manufacturing method are 185 MPa and 615 MPa, respectively, which are 1.5 times and 2.3 times under quasi-static strain. Finally, a complex tube structure made of 5356 aluminum alloy is successfully prepared by the additive subtractive hybrid manufacturing method, maintaining a surface roughness at the sub-micron level. The feasibility of the method in manufacturing complex components made of 5356 aluminum alloy, and relevant experimental data are accumulated, providing valuable experience and guidance for the future fabrication of other complex components.

Key words: additive and subtractive hybrid manufacturing, 5356 aluminum alloy, microstructures and properties, tube structure

CLC Number:

TG47

SONG Shida, QIAN Meixia, GUO Yiming, ZHANG Xiaoyong, WANG Kehong. Microstructure and Properties of 5356 Aluminum Alloy by Additive and Subtractive Hybrid Manufacturing[J]. Journal of Mechanical Engineering, 2025, 61(24): 118-128.

References

[1] LI S,ZHANG L J,NING J,et al. Comparative study on the microstructures and properties of wire+arc additively manufactured 5356 aluminium alloy with argon and nitrogen as the shielding gas[J]. Additive Manufacturing,2020,34:101206.
[2] ALDALUR E,SUAREZ A,VEIGA F,et al. Tomography analysis of Al-Mg alloys manufactured by wire-arc directed energy deposition with different metal transfer modes[J]. Alexandria Engineering Journal,2023,82:168-177.
[3] ALDALUR E,SUAREZ A,VEIGA F. Metal transfer modes for wire arc additive manufacturing Al-Mg alloys:Influence of heat input in microstructure and porosity[J]. Journal of Materials Processing Tech.,2021,297:117271.
[4] PAN J G,YUAN B,GE J G,et al. Influence of arc mode on the microstructure and mechanical properties of 5356 aluminum alloy fabricated by wire arc additive manufacturing[J]. Journal of Materials Research and Technology,2022,20:1893-1907.
[5] TOMAR B,SHIVA S,NATH T. A review on wire arc additive manufacturing:Processing parameters,defects,quality improvement and recent advances[J]. Materials Today Communications,2022,31:103739.
[6] SU C,CHEN X,GAO C,et al. Effect of heat input on microstructure and mechanical properties of Al-Mg alloys fabricated by WAAM[J]. Applied Surface Science,2019,486:431-440.
[7] SINHA A K,PRAMANIK S,YAGATI K P. Research progress in arc based additive manufacturing of aluminium alloys-A review[J]. Measurement,2022,200:111672.
[8] ZHU K,WANG J,ZHANG W C,et al. Effect of deposition strategies on microstructures,defects and mechanical properties of 5356 aluminum alloy by wire arc additive manufacturing[J]. Transactions of Nonferrous Metals Society of China,2024,34:423-434.
[9] 朱贝贝,熊俊. 交叉件GTA填丝增材制造弧压检测与成形控制[J]. 机械工程学报,2019,55(15):17-23. ZHU Beibei,XIONG Jun. Arc voltage detection and forming control for crossing parts in GTA additive manufacturing[J]. Journal of Mechanical Engineering,2019,55(15):17-23.
[10] 高炼玲,余圣甫,禹润缜,等. 5356铝合金过渡端框电弧增材制造及组织与性能[J]. 机械工程学报,2020,56(8):28-36. GAO Lianling,YU Shengfu,YU Runzhen,et al. Study on arc additive manufacturing process and properties of 5356 aluminum alloy rocket booster module transition end frame[J]. Journal of Mechanical Engineering,2020,56(8):28-36.
[11] 王磊磊,吕飞阅,高转妮,等. 电弧增材制造2319铝合金交叉桁条结构微观组织与拉伸性能研究[J]. 机械工程学报,2023,59(1):267-277. WANG Leilei,LÜ Feiyue,GAO Zhuanni,et al. Microstructure and tensile properties of wire arc additive manufactured 2319 aluminum alloy cross-stringer structure[J]. Journal of Mechanical Engineering,2023,59(1):267-277.
[12] 王天琪,杨壮,李亮玉,等. 悬空特征结构件电弧增材制造成形及算法优化[J]. 焊接学报,2019,40(12):78-83. WANG Tianqi,YANG Zhuang,LI Liangyu,et al. Research on forming and welding technology of thick wall structure arc added material manufacturing[J]. Transactions of the China Welding Institution,2019,40(12):78-83.
[13] 王天琪,李天旭,李亮玉,等. 复杂结构薄壁件电弧增材制造离线编程技术[J]. 焊接学报,2019,40(5):42-47. WANG Tianqi,LI Tianxu,LI Liangyu,et al. Off-line programming technology for arc additive manufacturing of thin-walled components with complex structures[J]. Transactions of the China Welding Institution,2019,40(5):42-47.
[14] LIU J K,HUANG J Q,ZHENG Y F,et al. Challenges in topology optimization for hybrid additive-subtractive manufacturing:A review[J]. Computer-Aided Design,2023,161:103531.
[15] DEZAKI M L,SERJOUEI A,ZOLFAGHARIAN A,et al. A review on additive/subtractive hybrid manufacturing of directed energy deposition (DED) process[J]. Advanced Powder Materials,2022,1(4):100054.
[16] ZHANG W,SOSHI M,YAMAZAKI K. Development of an additive and subtractive hybrid manufacturing process planning strategy of planar surface for productivity and geometric accuracy[J]. International Journal of Advanced Manufacturing Technology,2020,109:1479-1491.
[17] CHERNOVOL N,SHARMA A,TJAHJOWIDODO T,et al. Machinability of wire and arc additive manufactured components[J]. CIRP Journal of Manufacturing Science and Technology,2021,35:379-389.
[18] ZHANG S,ZHANG Y Z,GAO M,et al. Effects of milling thickness on wire deposition accuracy of hybrid additive/subtractive manufacturing[J]. Science and Technology of Welding and Joining,2019,24(5):375-381.
[19] ZHANG S,GONG M C,ZENG X Y,et al. Residual stress and tensile anisotropy of hybrid wire arc additive-milling subtractive manufacturing[J]. Journal of Materials Processing Technology,2021,293:117077.
[20] BAIK S,GUPTA R K,KUMAR K S,et al. Temperature increases and thermoplastic microstructural evolution in adiabatic shear bands in a high-strength and high- toughness 10 wt.% Ni steel[J]. Acta Materialia,2021,205:116568.