An aluminium alloy (AA) cylinder measuring 145 mm diameter (∅) and 11 mm height was produced by wire and arc additive manufacturing (WAAM) using ER4043 filler wire and cold metal transfer (CMT) welding process. The macrostructure examination of the WAAM-processed cylinder revealed excellent bonding between the deposited layers without defects and exhibited superior structural integrity. The tensile strength and elongation percentage were recorded for 0°, 45°, and 90° orientations and enhanced properties were observed compared with wrought counterpart. The hardness of additive layers steadily varied from bottom to top in the range of 58 to 46 HV. The microstructure of multi-layer additive deposits comprised of equiaxed and columnar dendrite structures. The fractured tensile specimen was characterised using a scanning electron microscope (SEM), which showed the presence of dimple-like structures revealing the ductile fracture. Finite element (FE) analysis was conducted using abaqus welding interface plug-in to predict the stress, strain, and temperature distributions at various stages of additive layer depositions.

通过使用ER4043填充焊丝和冷金属转移（CMT）焊接工艺的焊丝和电弧增材制造（WAAM）生产了直径为145毫米（∅），高度为11毫米的铝合金（AA）圆柱体。经WAAM处理的圆柱体的宏观结构检查显示，沉积层之间的粘结力极佳，没有缺陷，并且具有出色的结构完整性。记录了0°，45°和90°取向的拉伸强度和伸长率，并观察到与锻造相比的增强性能。添加剂层的硬度从底部到顶部在58至46 HV的范围内稳定变化。多层添加剂沉积物的微观结构由等轴和柱状枝晶结构组成。使用扫描电子显微镜（SEM）对断裂的拉伸试样进行表征，表明存在酒窝状结构，显示出韧性断裂。使用abaqus焊接界面插件进行了有限元（FE）分析，以预测添加剂层沉积各个阶段的应力，应变和温度分布。