Tratamientos preventivos para la reducción de NO

5.2.1 Surface inspection and metallurgical analysis

Due to sub-optimal wire cleaning processes and issues related to waviness of the wires, inclusions and geometric inconsistencies are intermittently observed on the build surface. The inclusions in a previous layer will influence the melting stability and quality of subsequently deposited layers and may result in porosity and other defects in the multilayer deposition. Inclusions and depressions which are indicated in Figure 5.7 are generated mainly due to imperfections in the wire. Twisting of the wire also results in somewhat inconsistent wire feed rate.

Figure 5.7 Appearance of WAAM parts made with (1) wire No.3 (2) wire No.4 (3) wire No.5

The WAAM parts were transversely cut, as shown in Figure 5.8. The cross-section of the left part was ground and polished.

Void content was assessed by optical microscope on as polished specimens. The microstructure was elucidated while Keller’s etchant (190ml water, 2ml HF, 3ml HCl, and 5ml HNO3) was used. Grain size was measured along the vertical direction of the build by

using the mean linear intercept (MLI) method [74].

As shown in Figure 5.9, there are voids observed in the cross-sections of the WAAM parts made with the friction extruded wire. For all three samples, the upper region contains more voids than bottom lower region: why this is so is not obvious but may be related to the arc model type and changes in arc current with build height[63]. The void number, total void area, average void size and void area faction at different heights were calculated by ImageJ software and shown in Figure 5.10. The lower region contains a higher number of voids but the total area and the void fraction are relatively small. Middle and top region contain more, larger, voids: the largest void is over 50 m across.

Figure 5.10 Void number, area, average size and void fraction on the transverse cross- sections of WAAM parts

As shown in Figure 5.11, the microstructure of the builds is typical of arc weld deposited material. Grains were nearly equiaxed but slightly elongated in the vertical direction. On the boundary between the AA6061 walls and the AA5083 substrate, this vertical elongation is most obvious. The grain size of the highest build at the crown, middle and root is presented in Figure 5.11. The grains are largest at the root and smallest near the crown.

Figure 5.11 Microstructure and grain size distribution on the cross-section of WAAM sample No.5

5.2.2 Hardness Test

The Vickers hardness of No.4 and No.5 WAAM parts have been measured along the central vertical line on the transverse cross-section. Both as-made and after a standard 6061-T6 heat-treatment were tested to reveal the effort of heat-treatment on these samples. The hardness data are shown in Figure 5.12. Both of them give the same trend of hardness along the vertical direction. From crown to root, the value increases first and reaches a peak at 3mm from the top. Below three mm from the crown the hardness decreases to approximately 60-70 HV and remains stable. Below the boundary of the WAAM part and the 5083 substrate, the hardness of the substrate is higher than that of the wall. Comparing the result before and after heat treatment, the T6 heat treatment generally provides a minor

improvement on hardness but most regions remain far from the hardness of the standard 6061-T6 value 107HV.

Figure 5.12 Vickers hardness on vertical central line of transverse cross-sections of part No.4 and No.5

5.2.3 Tension Test

For both as-made and standard AA6061-T6 (18 hours at 160°C) conditions, longitudinal tensile specimens w ere machined from WAAM wall sample No.5. They were machined to the shape suggested by ASTM standard [81] and then horizontally sliced into 1mm thick tensile bars, see Figure 5.13 and Figure 5.14. At last, 400 grits sand paper was applied to smooth their surfaces. In order to perform digital image correlation (DIC) during

tension test, one side of the tensile bar was painted with white background and then black dots pattern, shown in Figure 5.15.

Figure 5.13 Geometry of sub-scale tensile bar

Figure 5.15 Painted tensile bar, gage area

A sub-scale material tester (Figure 5.16) and digital image correlation (Figure 5.17) were used to obtain stress-strain curves of all tensile bars. These tension tests were performed with 0.1mm/s displacement rate. Force was measured by a load cell instrumented on the sub-scale tester and recorded by computer via Labview software. Displacement field was captured and calculated by digital image correlation system. A CCD camera was employed to take pictures with 2Hz sampling rate during tension test. The focal length of the camera is 55mm, aperture number N=16, the circle of confusion

c=3.6e-3, subject distance is 120mm, depth of field is 0.55mm which is sufficient for this

test. After the experiment, pictures were analyzed by Vic2D DIC software to extract strain field history on the tensile bar. Thus, the local strain and elongation can be obtained.

Figure 5.16 sub-scale tension tester

Figure 5.17 Camera and lighting setup for digital image correlation

The elongation of tensile bars at different height are presented with porosity condition in Figure 5.18. The trends of elongation in both as-made and aged conditions are basically matching with voids fraction distribution.

Figure 5.18 Elongation and voids area fraction vs. height on cross-section

The ultimate tensile strength is presented together with hardness results in Figure 5.19. The strongest part of the wall has UTS over 340MPa at 3mm below the crown: this is higher than the UTS of standard 6061-T6, 310MPa. Comparing UTS values with the hardness result indicates that they have similar trends with regard to the position in the build.

Figure 5.19 Ultimate tensile stress and Vickers Hardness variation on different height position of WAAM sample No.5