Research Projects

Wire and arc additive manufacturing (WAAM) is a layer-by-layer deposition technique that melts metallic wire using a welding arc, making it time-efficient and cost-competitive. It is particularly useful for aluminum alloys, which are used in various sectors due to their high strength-to-weight ratio and ductility at room temperature. However, the process can cause heterogeneous deformations, potentially affecting material degradation and crack growth resistance. The cold metal transferred arc welding (CMTAW) process is a suitable alternative for WAAM, based on traditional gas metal arc welding (GMAW) technology, to reduce welding heat input. Residual stress in additive manufactured components is due to temperature difference, contraction and expansion due to cooling and heating, and the expansion co-efficient, leading to anisotropic mechanical properties and heterogeneous microstructures. Currently, research on WAAM aluminum alloys has focused on evaluating tensile properties and microstructural features. This project proposes to understand the effect of material anisotropy on fatigue and fracture toughness properties of WAAM-CMT aluminium alloy cylindrical components. The project will analyze the metallurgical characteristics of the components in different directions and regions, as well as their mechanical properties, fatigue crack initiation, propagation, fatigue life, and fracture toughness. The structure-properties correlation will also be conducted to understand the anisotropic characteristics of the components and their influence on their structural integrity.