JMEPEG (2021) 30:7762–7769 ÓASM International

https://doi.org/10.1007/s11665-021-05959-y 1059-9495/$19.00

Effect of Travel Speed on the Properties of Al-Mg

Aluminum Alloy Fabricated by Wire Arc Additive
Manufacturing
M.M. Tawfik, M.M. Nemat-Alla, and M.M. Dewidar

Submitted: 12 March 2021 / Revised: 11 May 2021 / Accepted: 22 May 2021 / Published online: 14 June 2021

Al-Mg aluminum alloy thin-wall components were deposited using wire + arc additive manufacturing
(WAAM). Gas tungsten arc welding (GTAW) was adopted using ER5356 wire as the filler metal to fabricate
components. Three travel speeds (TS) of 200, 320, and 500 mm/min were adopted to achieve changed heat
input. Its effects on microstructure characteristics and tensile behavior were studied. The microstructure of
alloys deposited with a TS of 500 mm/min contained fine and equiaxed grains compared with other
deposited alloys. The TS 500 mm/min had a good assisting influence of controlling the forming quality and
little pores, and cracks were observed. Alloys deposited at the TS 500 mm/min displayed higher mechanical
properties with an ultimate tensile strength (UTS) of 245.5 MPa and elongation of 35.28%. Besides,
changing the TS had a small effect on the microhardness with a value of 2.3Hv.

defects formed in the manufactured components (Ref 14) such

Keywords 5356 aluminum alloy, mechanical properties, porosity,
WAAM
1. Introduction
WAAM is a modern technology used for manufacturing
metal components at high deposition rates, rapid prototyping,
and precision (Ref 1-3). It results in high-strength parts with
flexibility and the ability to manage properties that would not
be possible by traditional methods, upon near-net-shape (Ref 4,
5). It depends on the principle of arc welding using electric arc
as the fusion source for melting the wire to produce metal parts
additively. The manner of depositing components by the
WAAM technique is building them layer-by-layer, which
results in material and cost-saving, due to the deposition of
material done only in the required position (Ref 6), in addition
to the fabrication of complicated geometries and large-scale
components compared to traditional ones, especially lattice
structures (Ref 7, 8).
Due to lightweight material properties, good fracture
toughness and formability, excellent mechanical properties of
aluminum alloys (Ref 9-11), they have been applied in
shipbuilding and airplane applications (Ref 12, 13). Recently,
because of the great development of WAAM, it is adopted for a
spacious range of aluminum alloys. However, there are some
M.M. Tawfik, Mechanical Engineering Department, Faculty of
Engineering, Kafrelsheikh University, Kafrelsheikh 33516, Egypt;
M.M. Nemat-Alla, Mechanical Engineering Department, Faculty of
Engineering, Kafrelsheikh University, Kafrelsheikh 33516, Egypt; and
New Cairo Technological University, Cairo 11511, Egypt; and
M.M. Dewidar, Mechanical Engineering Department, Faculty of
Engineering, Kafrelsheikh University, Kafrelsheikh 33516, Egypt; and
Higher Institute of Engineering and Technology, Kafrelsheikh 33516,
Egypt. Contact e-mail: eng_mahmoudtawfik88@yahoo.com.
as porosity, anisotropic properties (Ref 15), inter-layer bonding
(Ref 16, 17), and coarse grains (Ref 18), which need more
investigations. The defects encountered in Al alloys fabricated
by the WAAM technique are similar to those that other alloys
encounter in fusion welding processes. However, the WAAM
of aluminum alloys has some drawbacks, such as a lack of
building uniformity, anisotropic properties, and widespread
defects in the deposited component. So, more researchers give
more attention for the fabrication of aluminum alloys by the
WAAM technique (Ref 19-22).
Silva et al. (Ref 23) applied WAAM technology for the
AA5083 alloy to study its formability for investigating its
potential applications. Decreasing the porosity formation in
aluminum alloys deposited using WAAM can be done by
making a plate and wire cleaning, torch-setting angle, the
cleanness of protection gas, polarity, and welding parameters
(Ref 24-27). Cong et al. (Ref 28) concluded that process
parameters should be suitably selected to control the deposited
component dimensions and resulted in porosity. The deposition
stability of the WAAM process was significantly affected by
wire quality (Ref 29). Zhao et al. (Ref 30) optimized the
geometry quality model for WAAM using an adaptive multi-
objective gray wolf algorithm. To get the optimal WAAM
process parameters for obtaining the desired geometry quality,
the obtained Pareto set was analyzed using the TOPSIS
algorithm. Horgar et al. (Ref 31) used two combinations of
WAAM process parameters for fabricating aluminum compo-
nents using the AA 5183 wire. They reported that there was
some cracking in the weld metals due to repeated reheating of
subsequent layers, usual porosity, and mean values of the yield
strength (YS) and UTS were 145 and 293 MPa, respectively.
Qi et al. (Ref 32) fabricated Al-Cu-Mg alloys with various
compositions by controlling the WFS during WAAM using
ER2319 (Cu content) and ER5087 (Mg content) as the filler
wires. It was obtained that with a higher Cu/Mg ratio, the
mechanical behavior had been enhanced (UTS: 280 ± 5 MPa,
and YS: from 156 MPa to 187 MPa). In the work of Yuan et al.

7762—Volume 30(10) October 2021 Journal of Materials Engineering and Performance

(Ref 33), the evaporation or burning of elemental Mg of 5356
Al-Mg alloys caused a variation of mechanical performances
and the final chemical composition of the fabricated compo-
nent. As the current increases, the elemental Mg loss rate
increases, which has a bad effect on the tensile strength and the
average hardness of manufactured components. The increase in
TS has the opposite effect on the Mg loss rate. Abe et al. (Ref
34) reported that the obtained mitigation ratio, filler wire
materials, and base metal composition can contribute to the
prediction of the final chemical composition for the deposited
component.
Duarte et al. (Ref 35) developed a novel WAAM variant
named Ultracold-WAAM. The electric arc in the new variant of
WAAM was established between a non-consumable tungsten
electrode and the filler wire instead of the substrate. It was
concluded that the process temperatures can be reduced using
the new WAAM variant, which increased the cooling rate of the
deposited parts, due to the removal of the electric current
through the substrate and moving the electric arc away from the
molten pool. These features of the new strategy can eliminate
defects such as distortion and periodic microstructure of the
deposited parts, which are caused due to the higher process
temperatures and lower cooling rates of conventional WAAM
processes. Mechanical testing of the deposited parts showed
that this strategy can preserve their ductility and their
mechanical strength.
Zhou et al. (Ref 36) proposed an indirect arc generated in
confined space between two tungsten electrodes and investi-
gated the impacts on decreasing the defects caused due to
excessive heat input. The arc plasma and molten droplets were
both expelled with regulated trajectories from a ceramic nozzle
under forced compression and thermal compression. The heat
input was greatly reduced since no arc was formed between the
wire and the substrate. It was concluded that during the entire
process, the compressed arc has a further heating impact on the
liquid metal droplets, which can improve inter-layer bonding
and reduce porosity.
Su et al. (Ref 37) deposited 4043 Al-5Si aluminum alloys
using the WAAM-CMT process by adopting Line 90°, Cycle
Line 90°, and Line 45° deposition strategies. It is concluded
that the phase composition of all fabricated alloys was the
same. However, the layer size, grain size, and Si morphology of
each deposited portion were different due to resulted cooling
rates of the employed strategy. The excellent strength (UTS of
223.2 MPa and YS of 141.8 MPa) had been shown with the
Line 45° strategy, but it displayed the lowest elongation (El of
10.6%). Panchenko et al. (Ref 38) developed a high-perfor-
mance WAAM process by modifying the waveforms of the
voltage and current. The aim of the modified process was to
increase the efficiency and productivity at high WFS and TS for
fabrication of Al-Mg-Mn alloying system. The generated heat
input of the process decreased due to the combined effect of the
increased TS and modified waveforms, which had a positive
impact on the deposited metal’s properties.
Based on the above literature and for the good knowledge of
the authors, there are not enough studies on the effect of
varying the travel speed on a wide range on the mechanical
behavior of 5356 Al-Mg aluminum alloy with overcoming the
defects such as porosity, cracks, and distortion. As a result, in
this study, we aimed to reduce these defects to enhance the
mechanical properties of Al-Mg aluminum alloy. Hence, Al-Mg
aluminum alloy thin-wall components had been built using the
WAAM technique. The effects of the WAAM process TS on
Journal of Materials Engineering and Performance
microstructure characteristics, microhardness, and tensile prop-
erties of the deposited components were studied.
2. Experimental Methods
2.1 Materials
In this study, ER5356 aluminum wire with a diameter of 1.2
mm was used as depositing material. AA6061-T6 aluminum
plate was adopted as a substrate with a thickness, length, and
width of 150, 100, and 10 mm, respectively. The chemical
compositions of the wire and subtract are illustrated in Table 1.
2.2 WAAM Process
To study the effects of TS on the properties of Al-Mg
aluminum alloy, thin-wall components were deposited with an
approximate length and height of 120 mm and 30 mm,
respectively. A schematic diagram of the experimental setup for
depositing the walls is illustrated in Figure 1(a). A GTAW
apparatus with a 250 A power source (INV AC-DC PULSE
TIG 250 A) was adopted to be the heat source. The GTAW
torch is mounted on a three-axis CNC milling machine to
perform the WAAM process. The surface of the substrate plate
was cleaned with acetone to remove oil and grease before
processing. While the other parameters remained unchanged,
three different TS were chosen. Additionally, the electric
current was kept at 160A. The deposition parameters used for
this study are presented in Table 2.
2.3 Testing Method
The sectioning of samples for the required tests is shown in
Figure 1(b). The specimens for the microstructure and micro-
hardness tests were well ground with abrasive paper with grits
of 400, 800, 1200, and 2500. Then, it was polished and etched
with an etchant of (25 ml CH3OH, 25 ml HCl, 25 ml HNO3,
and 1 drop HF). X-ray diffraction (XRD) tests were done with
an X-ray diffractometer (SHIMADZU 6000) to detect the
interior process. For the microstructure investigation, an optical
microscope and scanning electron microscope (SEM)
(JEOLJSM IT-100) were used. VickerÕs microhardness testing
machine (Mitutoyo HM-210A series) was used to run the
microhardness test with a 500-g load and a 10-s dwell time.
From the main sample, three tensile test specimens parallel to
the welding path were prepared. The dimensions of the tensile
test specimen are shown in Figure 1(c). A universal testing
machine (LLOYD, LR300K) was used to perform tensile
property tests with a 1 mm/min loading rate at room
temperature. The fracture surfaces of the tensile test specimens
were evaluated using SEM.
3. Results and Discussion
3.1 Microstructure
To understand the effects of the TS value on microstructure,
optical micrographs were taken for WAAM-processed 5356 Al-
Mg alloy, as shown in Fig. 2. It is found that the microstructure
of the WAAM-processed 5356 Al-Mg alloy had clear layer
characteristics, and its distribution along the direction of the
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Table 1 Chemical compositions of AA6061-T6 substrate and ER5356 aluminum wire (wt.%)
Elements Si Fe Cu Mg Ti Zn Mn Cr Al

Substrate 0.534 0.493 0.230 1.00 0.116 0.0076 0.0081 0.242 Bal.
ER5356 0.25 0.4 0.1 4.5-5.5 0.06-0.20 0.1 0.05-0.20 0.05-0.20 Bal.

Fig. 1 (a) Schematic diagram of the experimental setup of WAAM process, (b) tensile, microstructure, XRD, and microhardness specimenÕs
positions, and (c) the dimensions for tensile test specimen

Table 2 Deposition parameters building is periodic. Every deposited layer was split into two
regions: the inner-layer region and the inter-layer region. The
Parameter Value reasons for forming these characteristics are the cooling rate of
the deposited part and the temperature gradient around the bath.
Welding current type AC The inter-layer region had a refined grain structure, while
Alternating current frequency 50 Hz the inner-layer region had a coarse grain structure. In the inter-
WFS 6 m/min
layer region, it can be observed from Fig. 2(a, b, and c) that the
TS 200, 320, 500 mm/min
Argon 99.99% purity
microstructural characteristics revealed tiny columnar grains
Shield gas flow rate 15 L/min and fine equiaxed grains with non-standardized characteristics.
Current intensity 160 A Such results were reported by (Ref 39). Figure 2(d), (e), (f)
Tungsten electrode diameter 2.4 mm reveals that most grains formed in the inner-layer region were
coarse and equiaxial. Besides, the distribution of some
elongated grains showed coarse and columnar sizes along the
divide of the inter-layer boundary. The explanation for that is as

7764—Volume 30(10) October 2021 Journal of Materials Engineering and Performance

Fig. 2 Microstructure of inter-layer region and inner-layer region of the deposited samples using different TS using OM: (a), (d) 200 mm/min,
(b), (e) 320 mm/min, and (c), (f) 500 mm/min
the TS increases, the heat input into layers decreases, causing
the weld pool to cool and solidify faster.
Also, the microstructure of the inter-layer region and that
along its boundary showed some cracks and pores that can have
a bad effect on the mechanical properties, as shown in Fig. 2
and 3. The presence of hydrogen, which primarily comes from
the air and the filler wire, is the primary cause of pores formed
in the arc welding of aluminum alloys. Pores were observed to
be more formed by decreasing the TS from 300 to 200 mm/min.
As a result, the volume fraction of pores is proportional to the
amount of heat input, which varies with changing TS (Ref 22).
The reason for some cracking in the weld metals was repeated
reheating of subsequent layers. The mechanical properties of
the deposited Al-Mg alloys were influenced by these pores and
cracks. Using TS of 500 mm/min, little pores and cracks were
detected when compared to other TS. As a result, we concluded
that a TS of 500 mm/min has a significant assisting effect on the
deposited Al-Mg alloy forming quality.
SEM images of the Al-Mg samples deposited by WAAM
are presented in Figure 3. The XRD results of the Al-Mg
samples deposited by WAAM are illustrated in Figure 4. From
Journal of Materials Engineering and Performance
SEM images and XRD patterns, there were two main phases,
the a-phase (Al) and the b-phase (Al3Mg2) in the deposited
materials. b-phase (Al3Mg2) is distributed along the grain
boundaries, and others are scattered in grains. As shown from
XRD results, from the peaks, there was the promotion of ß-
phase orientation with increasing TS value from 200 to 500
mm/min. The reason for promoting ß-phase orientation with
increasing TS value is the decrease in evaporation or burning of
elemental Mg, as concluded by Yuan et al. (Ref 33). The
authors concluded that increasing the TS would result in the
promotion of ß-phase orientation and a lower Mg loss rate,
which would improve the mechanical properties of the
deposited Al-Mg alloy.
3.2 Microhardness
The microhardness results of the WAAM-deposited samples
along the deposition direction at various TS values are shown
in Fig. 5. Because the microstructure distribution along the
direction of the building is periodic, microhardness is exceed-
ingly associated with the microstructure as confirmed in many
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Fig. 3 SEM images of b phase and porosity in the Al-Mg alloy deposited using different TS: (a) 200 mm/min, (b) 320 mm/min, and (c) 500
mm/min
Fig. 4 XRD results of the Al-Mg samples deposited by WAAM
studies (Ref 40-42). The microhardness results of the deposited
specimens are also periodically distributed and varied with the
change in the deposition height; such results were confirmed by
[39]. The microhardness value of inter-layer regions was
greater than that of the inner-layer regions, due to the refined
grains in the inter-layer regions, which made the standard
deviation of the microhardness reading relatively large. The
mean microhardness values were 70.71± 4.61, 71.75± 5.69,
and 73.01± 3.65 HV, respectively, at the TS 200, 320, and 500
mm/min.
The average microhardness of deposit samples increased
with increasing TS, as presented in Fig. 5. However, changing
7766—Volume 30(10) October 2021
Fig. 5 The microhardness results along the building direction of
the WAAM-deposited samples at different TS values
TS only had a small influence on the microhardness results
(small changes of the order of 2.3Hv). The Mg content in Al-
Mg alloy affects its mechanical properties, and its presence is
directly proportional to those properties, as concluded by
previous research (Ref 43). During the metal transfer, the Mg
element evaporates where the temperature is above the boiling
point (1107 °C) (Ref 44). Additionally, the heat input increases
with a decrease in the TS, which can increase the temperature
above the boiling point of Mg and lower the solidification rate.
So, this increase in microhardness occurred, because with an
Journal of Materials Engineering and Performance
increase in the TS, the grain refinement increases, and the Mg
loss rate of Al-Mg alloys decreases, as obtained by (Ref 33)
3.3 Tensile Properties
To study how TS affects the mechanical properties of the
deposited Al-Mg alloy, the deposited alloy material was
conducted for tensile testing. UTS and elongation results of
the fabricated Al-Mg alloy at 200, 320, and 500 mm/min TS are
illustrated in Fig. 6. The deposited Al-Mg alloy has UTS values
ranging from 212.5 to 245.5 MPa with increasing TS 200 to
500 mm/min. Also, EL increased with the same trend of UTS
from 20.68% to 35.28%. We, as authors, conclude that the grain
refinement mechanism occurred when the TS value increased
from 200 to 500 mm/min leading to this improvement in the
Fig. 6 Tensile properties of WAAM-deposited Al-Mg components
Fig. 7 SEM images of fracture features of deposited Al-Mg alloys at a TS rate of (a) 200 mm/min, (b) 320 mm/min, and (c) 500 mm/min
Journal of Materials Engineering and Performance
tensile property. It was observed that the deposition of Al-Mg
alloy using ER5356 by the WAAM process enhanced mechan-
ical behavior compared with the 5356 alloys manufactured by
casting process; 5356 casting alloys have UTS of 202.35 and
EL of 23.78% (Ref 45).
The SEM images of the fabricated Al-Mg alloy’s fracture
appearance are shown in Fig. 7. Fracture surfaces contained
pores and second cracks. The plasticity and the load-carrying
capacity were decreased due to the presence of these pores. The
noticed fracture mode of the deposited samples at TS rates of
320 and 500 mm/min was the dimple fracture, and it is a typical
ductile fracture. However, the deposited sample with a TS value
of 200 mm/min displayed an intergranular mode of fracture,
which presented typical brittle fracture characteristics. The
particles of b-phase, which are located in the dimples, are the
main source for cracks. Pores are also responsible for the
initiation and expansion of cracks, and these cracks cause
fracture; such results are similar to the previous study by Gu
et al. (Ref 46). It was observed that by increasing the TS value
the number and size of unit area dimples increased. Therefore,
the mechanical properties of the WAAM-deposited Al-Mg
alloy were the best at TS of 500 mm/min.
4. Conclusions
In this study, the fabrication of Al-Mg alloys was success-
fully achieved using the WAAM technique. The effects of TS
on their microstructural characteristics, microhardness, and
tensile properties were studied. The following conclusions are
summarized:
Volume 30(10) October 2021—7767
1. The microstructure of the WAAM-processed Al-Mg alloy
had clear layer characteristics, and its distribution along
the direction of the building is periodic.
2. TS of 500 mm/min has a good assisting influence of
valuably controlling the forming quality, and little pores
and cracks were observed.
3. The inner-layer regions had coarse grains, and the inter-
layer regions had refined equiaxed grains. The trend of
grain growth was significantly slowed down with increas-
ing TS.
4. The changing of TS value had a small effect on the
microhardness value (small changes of the order of
2.3Hv).
5. The deposited Al-Mg alloy has UTS values ranging from
212.5 to 245.5 MPa with increasing TS 200 to 500 mm/
min. Also, EL increased with the same trend of UTS
from 20.68% to 35.28%.
6. The deposited alloys exhibited enhanced mechanical
behavior compared with the 5356 alloys manufactured by
the casting process; 5356 casting alloys have UTS of
202.35 and EL of 23.78% (Ref 45).
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