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Meeting 2022 TMS Annual Meeting & Exhibition
Symposium Defects and Properties of Cast Metals IV
Presentation Title Modification of Cast and Wrought Aluminum Parts Using Hybrid Laser Hot-wire Manufacturing
Author(s) Gerry L. Knapp, Thomas Feldhausen, Ying Yang, Benjamin Stump, Donovan Leonard, Alex Plotkowski
On-Site Speaker (Planned) Gerry L. Knapp
Abstract Scope Die-casting and hydroforming of aluminum parts are critical manufacturing processes for automotive applications. However, aluminum alloys with desirable specific strength or wear resistance are not always formable in the desired geometries. We used laser hot-wire hybrid manufacturing to create locally modified cast and wrought aluminum alloy substrates by depositing and machining dissimilar aluminum alloy features. Preliminary work focused on determining printable wire alloys and characterization of the interface of the deposited material with the substrates. High throughput thermodynamic calculations using a multi-component Al alloy database helped screen combinations of wire and substrate alloys based on material hot cracking sensitivity at the interface. Al 4043 wire was chosen for high printability with cast A356 alloy ingot and 6111 plates as substrates. Mechanical testing and characterization of the interface region were performed. This work was supported by the U.S. Department of Energy – Vehicle Technology Office Light Metals Core Program.
Proceedings Inclusion? Planned:
Keywords Additive Manufacturing, Aluminum, Mechanical Properties


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