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Welding and Additive Manufacturing with Nanoparticle-Enhanced Aluminum 7075 Wire.

Daniel Oropeza¹, Douglas C Hofmann¹, Kyle Williams¹

¹Engineering and Science Directorate, Jet Propulsion Laboratory, California Institute of Technology, 4800 Oak Grove Dr, Pasadena, CA 91109, USA.

Journal of Alloys and Compounds

|July 15, 2020

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Nanoparticle additives enable the processing of high-strength Aluminum alloy 7075 (Al 7075) using welding and additive manufacturing. This research demonstrates the recovery of T73 properties in these processed Al 7075 components.

Area of Science:

Materials Science
Metallurgy
Manufacturing Engineering

Background:

Aluminum alloy 7075 (Al 7075) with T73 heat treatment is vital in aerospace for its high specific strength.
Traditional melt processing (welding, casting, additive manufacturing) of Al 7075 is challenging due to solidification issues.

Purpose of the Study:

To investigate the properties of nanoparticle-enhanced Al 7075 in welded and additively manufactured forms.
To assess the feasibility of recovering Al 7075 T73 properties in components processed via novel methods.

Main Methods:

Utilized nanoparticle additives to control solidification in Al 7075.
Investigated nanoparticle-enhanced Al 7075 in welded parts, overlays, and wire-based additive manufacturing.
Measured hardness and tensile strength in as-welded and T73 heat-treated conditions.

Keywords:

3D printing Aluminum 7075 arc welding wire-fed additive manufacturing

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Main Results:

Demonstrated successful processing of Al 7075 via welding and additive manufacturing using nanoparticle additives.
Recovered the characteristic hardness and tensile strength of Al 7075 T73 in welded and layer-deposited parts.
Achieved high-strength, crack-free Al 7075 components through these advanced manufacturing techniques.

Conclusions:

Nanoparticle additives facilitate the melt processing of Al 7075 for advanced manufacturing applications.
Al 7075 can now be conventionally welded or additively manufactured into high-performance parts.
This breakthrough expands the manufacturing possibilities for high-strength aluminum alloys in aerospace and beyond.