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Development of AMC Welding Wire and Inline Hot Rolling for Enhanced Properties of DED-Arc/Wire-Manufactured Parts

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Abstract:

The wire arc directed energy deposition (DED-Arc/wire) process offers great potential for the additive manufacturing of large-volume components thanks to high deposition rates and cost-effective plant technology. Aluminium matrix composites (AMCs) are a high-performance alternative to conventional aluminium alloys, but their use in additive manufacturing has been limited so far due to porosity, restricted mechanical properties and a lack of semi-finished wire products. This paper presents a resource-efficient inline process chain for the additive manufacturing of silicon carbide-reinforced (SiC) AMCs (AMC-SiC). Since commercial AMC-SiC welding wires are not available, an AMC-SiC wire was produced from an aluminium tube (AW-6060) filled with AMC-SiC chips by means of multi-stage rotary swaging to a diameter of 1.6 mm. The DED-Arc/wire welding tests carried out demonstrate the basic processability of the developed wire, but with pronounced porosity in the weld seam. By integrating an inline hot rolling process, the weld bead was significantly deformed and the porosity was significantly reduced, thereby expanding the application potential of additively manufactured AMC-SiCs.

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Info:

Periodical:

Key Engineering Materials (Volume 1047)

Pages:

231-241

Online since:

April 2026

Authors:

Tim Sebastian Tübbicke*, Fabian Dittrich, Sebastian Härtel

Keywords:

Additive Manufacturing, AMC, Inline Hot Rolling

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Permissions:

Creative Commons CC BY 4.0

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* - Corresponding Author

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