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Process–Microstructure–Property Characteristics of Aluminum Walls Fabricated by Hybrid Wire Arc Additive Manufacturing with Friction Stir Processing.

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Title: Process–Microstructure–Property Characteristics of Aluminum Walls Fabricated by Hybrid Wire Arc Additive Manufacturing with Friction Stir Processing.
Authors: Elalem, Ahmed Nabil1 (AUTHOR) nabil01@hotmail.com, Wu, Xin1 (AUTHOR)
Source: Materials (1996-1944). Feb2026, Vol. 19 Issue 3, p580. 25p.
Subjects: Friction stir processing, Microstructure, Electric welding, Aluminum alloys, Mechanical behavior of materials, Heat treatment
Abstract: Wire Arc Additive Manufacturing (WAAM) is a cost-effective method for fabricating large aluminum components; however, it tends to suffer from heat accumulation and coarse anisotropic microstructures, which can limit the part's performance. In this study, a wall is fabricated using a hybrid unified additive deformation manufacturing process (UAMFSP) method, which integrates friction stir processing (FSP) into WAAM, and is compared with a Metal Inert Gas (MIG)-based WAAM wall. Infrared (IR) thermography revealed progressive heat buildup in MIG walls, with peak layer temperatures of about 870 to 1000 °C. In contrast, in the UAMFSP process, heat was redistributed through mechanical stirring, maintaining more uniform sub-solidus profiles below approximately 400 °C. Also, optical microscopy and quantitative image analysis showed that MIG walls developed coarse, dendritic grains with a mean grain area of about 314 µm2, whereas the UAMFSP produced refined, equiaxed grains with a mean grain area of about 10.9 µm2. Microhardness measurement (Vickers HV0.2, 200 gf) confirmed that the UAMFSP process can improve the hardness by 45.8% compared to the MIG process (75.8 ± 7.7 HV vs. 52.0 ± 1.3 HV; p = 0.0027). In summary, the outcomes of this study introduce the UAMFSP process as a method for addressing the thermal and microstructural limitations of WAAM. These findings provide a framework for further extending hybrid additive–deformation strategies to thicker builds, alternative alloys, and service-relevant mechanical evaluations. [ABSTRACT FROM AUTHOR]
Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Label: Title
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  Data: Process–Microstructure–Property Characteristics of Aluminum Walls Fabricated by Hybrid Wire Arc Additive Manufacturing with Friction Stir Processing.
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  Data: <searchLink fieldCode="AR" term="%22Elalem%2C+Ahmed+Nabil%22">Elalem, Ahmed Nabil</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> nabil01@hotmail.com</i><br /><searchLink fieldCode="AR" term="%22Wu%2C+Xin%22">Wu, Xin</searchLink><relatesTo>1</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. Feb2026, Vol. 19 Issue 3, p580. 25p.
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  Data: <searchLink fieldCode="DE" term="%22Friction+stir+processing%22">Friction stir processing</searchLink><br /><searchLink fieldCode="DE" term="%22Microstructure%22">Microstructure</searchLink><br /><searchLink fieldCode="DE" term="%22Electric+welding%22">Electric welding</searchLink><br /><searchLink fieldCode="DE" term="%22Aluminum+alloys%22">Aluminum alloys</searchLink><br /><searchLink fieldCode="DE" term="%22Mechanical+behavior+of+materials%22">Mechanical behavior of materials</searchLink><br /><searchLink fieldCode="DE" term="%22Heat+treatment%22">Heat treatment</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: Wire Arc Additive Manufacturing (WAAM) is a cost-effective method for fabricating large aluminum components; however, it tends to suffer from heat accumulation and coarse anisotropic microstructures, which can limit the part's performance. In this study, a wall is fabricated using a hybrid unified additive deformation manufacturing process (UAMFSP) method, which integrates friction stir processing (FSP) into WAAM, and is compared with a Metal Inert Gas (MIG)-based WAAM wall. Infrared (IR) thermography revealed progressive heat buildup in MIG walls, with peak layer temperatures of about 870 to 1000 °C. In contrast, in the UAMFSP process, heat was redistributed through mechanical stirring, maintaining more uniform sub-solidus profiles below approximately 400 °C. Also, optical microscopy and quantitative image analysis showed that MIG walls developed coarse, dendritic grains with a mean grain area of about 314 µm2, whereas the UAMFSP produced refined, equiaxed grains with a mean grain area of about 10.9 µm2. Microhardness measurement (Vickers HV0.2, 200 gf) confirmed that the UAMFSP process can improve the hardness by 45.8% compared to the MIG process (75.8 ± 7.7 HV vs. 52.0 ± 1.3 HV; p = 0.0027). In summary, the outcomes of this study introduce the UAMFSP process as a method for addressing the thermal and microstructural limitations of WAAM. These findings provide a framework for further extending hybrid additive–deformation strategies to thicker builds, alternative alloys, and service-relevant mechanical evaluations. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.3390/ma19030580
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      – Code: eng
        Text: English
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        PageCount: 25
        StartPage: 580
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        Type: general
      – SubjectFull: Microstructure
        Type: general
      – SubjectFull: Electric welding
        Type: general
      – SubjectFull: Aluminum alloys
        Type: general
      – SubjectFull: Mechanical behavior of materials
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      – SubjectFull: Heat treatment
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      – TitleFull: Process–Microstructure–Property Characteristics of Aluminum Walls Fabricated by Hybrid Wire Arc Additive Manufacturing with Friction Stir Processing.
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            NameFull: Elalem, Ahmed Nabil
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            NameFull: Wu, Xin
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              M: 02
              Text: Feb2026
              Type: published
              Y: 2026
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              Value: 19
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