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A novel bypass-gas metal arc directed energy deposition for in-situ synthesis Al–Cu–Li alloy

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A novel bypass-gas metal arc directed energy deposition (bypass-GMA DED) was proposed to prepare high strength Al–Cu–Li-based components. An Al–5.51Cu–0.48Li alloy was successfully prepared, followed by subsequent T6 treatment. The microstructure evolution and improvement of mechanical properties after the T6 state were benchmarked against the as-deposited condition. The component fabricated by bypass-GMA DED has obvious periodic distribution characteristics, with a large number of fine equiaxed grains distributed near the interlayer fusion boundary and coarse columnar grains within the intralayer region. After heat treatment, the Al–5.51Cu–0.48Li alloy is mainly composed of four types of strengthening phases, θ′, θ″, δ′ and T1, which contrasts with the sole presence of θ phase in the deposited condition. These phases are conducive to the improvement of mechanical properties. The strength of the prepared alloy is higher than those additively manufactured Al–Cu–Li alloys, reaching values similar to those of conventional third generation Al–Cu–Li alloys.

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This work was supported by National Natural Science Foundation of China [grant number 52475343], Central Guidance for Local Scientific and Technological Development Funding Projects [grant number 246Z1015G] and Natural Science Foundation of Hebei Province [grant number E2024208049]. Publisher Copyright: © 2025 The Author(s). Published by Informa UK Limited, trading as Taylor & Francis Group.

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Al–Cu–Li alloy Bypass-gas metal arc directed energy deposition (bypass-GMA DED) intermediate alloys mechanical properties microstructure Signal Processing Modelling and Simulation Computer Graphics and Computer-Aided Design Industrial and Manufacturing Engineering

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