Wire-arc additive manufacturing of AZ31 magnesium alloy fabricated by cold metal transfer heat source: Processing, microstructure, and mechanical behavior

The modified cold metal transfer (CMT) heat sources by adjusting the characteristic processing parameters were conducted in wire-arc additive manufacturing (WAAM) of AZ31 magnesium alloy for thin-wall component. The processing, microstructure, and mechanical behaviour were investigated. The CMT characteristic deposited a wide and shallow weld bead coupled with good wettability and low equivalent heat input was selected for CMT-WAAM process. The microstructure of thin-wall component showed obvious layer characteristics, which consisted of the deposited layers with fine columnar dendrite grains and the HAZ interlayers with coarse equiaxed grains and some pores. The thin-wall component exhibited anisotropic tensile properties with lower yield strength, higher elongation, and higher ultimate tensile strength in the deposition direction than in the build direction. CMT-WAAM component of AZ31 magnesium alloy has an accepted mechanical property compared with the as-forged and as-cast components. To improve the component strength, minimizing the softening effect of the HAZ interlayers by preventing grain coarsening and suppressing porosity is essential.