Comparative Study on Wire-Arc Additive Manufacturing and Conventional Casting of Al–Si Alloys: Porosity, Microstructure and Mechanical Property

Here, we compare the porosity, microstructure and mechanical property of 4047 Al–Si alloys prepared by wire-arc additive manufacturing (WAAM) and conventional casting. X-ray microscopy reveals that WAAM causes a higher volume fraction of gas pores in comparison with conventional casting. Effective refinements of α-Al dendrites, eutectic Si particles and Fe-rich intermetallic compounds are achieved by WAAM, resulting from its rapid solidification...