The strengthening effect of inter-layer cold working and post-deposition heat treatment on the additively manufactured Al-6.3Cu alloy

Wire + Arc Additive Manufacture (WAAM) attracts great interest from the aerospace industry for producing components with aluminum alloys, particularly Al-Cu alloy of the 2000 series such as 2219 alloy. However the application is restricted by the low strength properties of the as-deposited WAAM metal. In this study two strengthening methods were investigated - inter-layer cold working and post-deposition heat treatment. Straight wall samples were prepared with 2319 aluminum alloy wire. Inter-layer rolling with loads of 15 kN, 30 kN and 45 kN were employed during deposition. The ultimate tensile strength (UTS) and yield strength (YS) of the inter-layer rolled alloy with 45 kN load can achieve 314. MPa and 244. MPa respectively. The influence of post-deposition T6 heat treatment was investigated on the WAAM alloy with or without rolling. Compared with inter-layer rolling, post-deposition heat treatment can provide much greater enhancement of the strength. After T6 treatment, the UTS and YS of both of the as-deposited and 45 kN rolled alloys exceeded 450. MPa and 305. MPa respectively, which are higher than the properties of the wrought 2219-T6 alloy. The strengthening mechanisms of this additively manufactured Al-6.3Cu alloy were investigated through microstructure analysis

Wire+Arc Additive Manufacturing of Aluminum

Wire+Arc Additive Manufacturing is very suitable for the production of large scale aluminium parts. However implementation is currently limited by issues such as porosity and low mechanical properties. We have studied the utilization of new deposition processes such as pulsed advanced cold metal transfer which allows modification of the thermal profile resulting in refined equiaxed microstructure and elimination of porosity. Standard and new feedstock compositions are being evaluated and developed with ultimate tensile strengths of up to 260 MPa with 17% elongation being obtained in the as-deposited condition. Post build heat treatments compositional changes and high-pressure inter-pass rolling are being investigated in order to increase the strength further.Mechanical Engineerin

Micropore evolution in additively manufactured aluminum alloys under heat treatment and inter-layer rolling

The application of wire + arc additively manufactured (WAAM) aluminum alloys has been restricted by the porosity defect, which is generally detrimental to the mechanical properties. Suppressing of micropores in the WAAM components has attracted considerable attention in recent years. Inter-layer rolling was introduced to eliminate micropores during the WAAM deposition of the Al–Cu6.3 and Al–Mg4.5 alloys. The distribution characteristics and individual morphology of micropores were revealed by the X-ray diffraction tomography. Key findings demonstrated that the number, volume, size, and roundness of micropores in rolled alloys decreased similarly with increasing loads, eventually achieving a density of over 99.9%. After the heat treatment, the homogeneous distribution of fine (around 5.3 μm) and spherical (0.70–0.74) micropores was realized in the 45 kN rolled alloys. All the evaluated indicators of micropores in the 45 kN rolled + heat treated alloys were superior to the post-deposition heat treated state. The evolution mechanisms include the reprecipitation of hydrogen pores, formation of vacant voids, and re-opening of unclosed pores. The hybrid technique of WAAM + rolling + heat treatment has great potential in promoting mechanical properties of WAAM alloys. The results will provide a theoretical guidance for the design of high-performance WAAM aluminum alloy components

Microstructure, defects, and mechanical properties of wire + arc additively manufactured AlCu4.3-Mg1.5 alloy

The wire with a composition of AlCu4.3%Mg1.5% was customized and used to deposit the WAAM alloy with the power source of cold metal transfer. The microstructure, defect, and mechanical properties of the as-deposited and heat-treated WAAM alloys were studied. Key findings demonstrated that the microstructure of the as-deposited alloy was characterized by a hierarchical distribution of dendrites, equiaxed grains, and a slight number of columnar grains. The volume fraction of the network-like scattered coarse particles of second phases θ + S reduced by 95% after the T6 heat treatment. With an average microhardness of 161.4 HV, the mean yield strength and ultimate tensile strength of the WAAM alloy increased by 116% and 66% achieving 399 MPa and 485 MPa in the horizontal direction after heat treatment. The precipitation of a high density of needle-shaped metastable S′ precipitates was responsible for the significantly enhanced mechanical properties. However, this WAAM alloy has exhibited an anisotropic tensile property. A considerable number of sharp-angled defects like linear and chain-like micropores, which generally depress the mechanical properties, were formed in the WAAM alloys

A solar wind-derived water reservoir on the Moon hosted by impact glass beads

The past two decades of lunar exploration have seen the detection of substantial quantities of water on the Moon’s surface. It has been proposed that a hydrated layer exists at depth in lunar soils, buffering a water cycle on the Moon globally. However, a reservoir has yet to be identified for this hydrated layer. Here we report the abundance, hydrogen isotope composition and core-to-rim variations of water measured in impact glass beads extracted from lunar soils returned by the Chang’e-5 mission. The impact glass beads preserve hydration signatures and display water abundance profiles consistent with the inward diffusion of solar wind-derived water. Diffusion modelling estimates diffusion timescales of less than 15 years at a temperature of 360 K. Such short diffusion timescales suggest an efficient water recharge mechanism that could sustain the lunar surface water cycle. We estimate that the amount of water hosted by impact glass beads in lunar soils may reach up to 2.7 × 1014 kg. Our direct measurements of this surface reservoir of lunar water show that impact glass beads can store substantial quantities of solar wind-derived water on the Moon and suggest that impact glass may be water reservoirs on other airless bodies

‘Seaweed appearance’ in squamous cell carcinoma of the penis: A new dermoscopic finding

Abstract Squamous cell carcinoma of the penis is an uncommon cancer. Vascular feature on dermoscopy is common in all forms of invasive squamous cell carcinoma, and the presence of the specific vascular features is often used to aid diagnosis. Here, we reported a new dermoscopic finding—seaweed‐like vascular pattern in squamous cell carcinoma of the penis

Application of bulk deformation methods for microstructural and material property improvement and residual stress and distortion control in additively manufactured components

Many additively manufactured (AM) materials have properties that are inferior to their wrought counterparts, which impedes industrial implementation of the technology. Bulk deformation methods, such as rolling, applied in-process during AM can provide significant benefits including reducing residual stresses and distortion, and grain refinement. The latter is particularly beneficial for titanium alloys where the normally seen large prior β grains are converted to a fine equiaxed structure – giving isotropic mechanical properties that can be better than the wrought material. The technique is also beneficial for aluminium alloys where it enables a dramatic reduction in porosity and improved ductility

Deformation microstructures and strengthening mechanisms for the wire+arc additively manufactured Al-Mg4.5Mn alloy with inter-layer rolling

Applying inter-layer rolling to the wire+arc additively manufacturing (WAAM) process with increasing loads of 15 kN, 30 kN and 45 kN, achieves excellent mechanical properties for 5087 (Al-Mg4.5-Mn) alloys. Compared with the as-deposited alloy, the average micro hardness, yield stress and ultimate tensile strength of 45 kN rolled alloys reached to 107.2 HV, 240 MPa and 344 MPa, which were enhanced by 40%, 69% and 18.2%, respectively. Primary coarse grain structures were found to become greatly refined with an evident rolling texture after deformation. The strengthening mechanisms mainly are deformation strengthening, grain refinement, and solution strengthening. Meanwhile, the elongation of rolled alloys stays over 20%. The plasticity was not obviously diminished compared with the as-deposited alloy. This is two times greater than the commercial wrought Al-Mg alloy with similar composition. The excellent plasticity may be chiefly due to grain refinement, pores closure and reduction, and grain recrystallization during the WAAM re-heating process. The combination process of rolling deformation with WAAM deposition is an effective technique in refining microstructure and improving mechanical properties for AM aluminum alloys