Abstract Hybrid Metal Extrusion and Bonding Additive Manufacturing (HYB-AM) is a new solid-state process for the production of 3D metal structures. In HYB-AM, the wire feedstock is continuously processed through an extruder and deposited in a stringer-by-stringer manner to form layers and eventually a near net-shape component. In this work, the layer bonding of AA6082 samples produced by this process has been investigated by means of tensile testing, hardness measurements and microscope analyses. Furthermore, a novel method for the fabrication of miniature tensile specimens for assessing the bond strength across the layers is presented and applied. The test results reveal that the ultimate tensile strength is approaching that of the substrate material of the same alloy, yet with a somewhat lower elongation prior to fracture. Microscope analyses show that the bonded interfaces are fully dense; however, the fracture surfaces reveal regions of kissing-bonds and lack of bonding. Still, these preliminary investigations indicate that the HYB-AM process, upon further optimization, has the potential of processing high quality aluminum alloy components.

中文翻译：

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通过混合金属挤压和粘合增材制造沉积的 AA6082 3D 结构的机械完整性

摘要 混合金属挤压和键合增材制造 (HYB-AM) 是一种用于生产 3D 金属结构的新型固态工艺。在 HYB-AM 中，线材原料通过挤出机连续加工，并以逐个纵梁的方式沉积以形成层，最终形成近净形部件。在这项工作中，通过拉伸试验、硬度测量和显微镜分析研究了由该工艺生产的 AA6082 样品的层粘合。此外，还提出并应用了一种用于制造用于评估跨层粘合强度的微型拉伸试样的新方法。测试结果表明，极限拉伸强度接近相同合金基材的极限拉伸强度，但断裂前的伸长率略低。显微镜分析表明键合界面完全致密；然而，断裂表面显示了接吻区域和缺乏粘合区域。尽管如此，这些初步调查表明，HYB-AM 工艺经过进一步优化，具有加工高质量铝合金部件的潜力。