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Rapid prototyping of 5356-aluminum alloy based on variable polarity gas tungsten arc welding: process control and microstructure

This paper concentrates on rapid prototyping of a 5356-aluminum alloy based on a new deposition process of variable polarity gas tungsten arc welding (VPGTAW), and describes the microstructure and geometrical properties of the deposited layers. The wettability and distortion tendency of the deposited layers is effectively improved by preheating the substrate up to 118°C, monitoring the arc-length, and adjusting the arc current during the deposition process. The relationships between the geometry of the deposited layers and the welding parameters are developed. The surface roughness of the deposited parts is found to be in the order of 2 μm. The deposited layers exhibit equiaxed dendrites at the top layer, fine equiaxed grains at the middle, and bottom of a deposited wall together with some precipitates distributed at the grain boundary regions, and coarse columnar grains at the bonding zone between the deposited wall and the substrate. The residual microstructure such as grain size and distribution of precipitates is highly dependent on the related locations in the deposited wall. The deposited samples possess a maximum hardness at the top layer and exhibit a slight decreasing trend towards the middle and bottom of the fabricated part due to the heat effects of the material that occurs during the deposition. By understanding these relationships between parameters and their effect on the process output, the process can be used more effectively and the quality be improved as well.