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Comparative Evaluation of Mechanical Behaviour and Machinability of WAAM-Fabricated Aluminium Alloys.

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Title: Comparative Evaluation of Mechanical Behaviour and Machinability of WAAM-Fabricated Aluminium Alloys.
Authors: Sundaram, Saravanamurugan1 (AUTHOR), Mohanavelu, Thenarasu1,2 (AUTHOR) a_sumesh@cb.amrita.edu, Arangot, Sumesh1 (AUTHOR), Petru, Jana2 (AUTHOR) cb.en.u4mee23033@cb.students.amrita.edu, Ruthramoorthy, Mohan1 (AUTHOR), Rowther, Rashaad Sabir1 (AUTHOR), Senthilkumar, Kamalesh1 (AUTHOR)
Source: Materials (1996-1944). Jun2026, Vol. 19 Issue 12, p2653. 19p.
Subjects: Mechanical behavior of materials, Machining, Aluminum alloys, Porosity, Tensile strength, Surface roughness, Manufacturing processes
Abstract: This study presents an integrated evaluation of the mechanical properties and machinability of thin-walled aluminium alloys fabricated via Wire Arc Additive Manufacturing (WAAM), comparing them against conventional wrought counterparts. Experimental investigations were conducted through tensile testing, hardness measurement, surface characterisation, and cutting force analysis. The results reveal a critical performance trade-off: WAAM specimens demonstrated superior bulk mechanical properties, most notably a 44.36% increase in tensile strength, alongside enhanced elongation despite a marginal reduction in hardness. However, this structural advantage is counterbalanced by a significant machinability penalty. Frequency domain analysis using Power Spectral Density (PSD) revealed that inherent microstructural porosity in WAAM components triggers dynamic instabilities during machining. These irregularities make the material highly susceptible to high-frequency chatter, ultimately resulting in a 46.73% increase in surface roughness. By establishing a direct relationship between fabrication-induced microstructural defects and dynamic machining degradation, these findings emphasise the necessity for defect-aware, optimised hybrid manufacturing strategies to improve the industrial applicability of WAAM-fabricated structures. [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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DbLabel: Engineering Source
An: 194907727
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  Data: Comparative Evaluation of Mechanical Behaviour and Machinability of WAAM-Fabricated Aluminium Alloys.
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  Data: <searchLink fieldCode="AR" term="%22Sundaram%2C+Saravanamurugan%22">Sundaram, Saravanamurugan</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Mohanavelu%2C+Thenarasu%22">Mohanavelu, Thenarasu</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<i> a_sumesh@cb.amrita.edu</i><br /><searchLink fieldCode="AR" term="%22Arangot%2C+Sumesh%22">Arangot, Sumesh</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Petru%2C+Jana%22">Petru, Jana</searchLink><relatesTo>2</relatesTo> (AUTHOR)<i> cb.en.u4mee23033@cb.students.amrita.edu</i><br /><searchLink fieldCode="AR" term="%22Ruthramoorthy%2C+Mohan%22">Ruthramoorthy, Mohan</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Rowther%2C+Rashaad+Sabir%22">Rowther, Rashaad Sabir</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Senthilkumar%2C+Kamalesh%22">Senthilkumar, Kamalesh</searchLink><relatesTo>1</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. Jun2026, Vol. 19 Issue 12, p2653. 19p.
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  Data: <searchLink fieldCode="DE" term="%22Mechanical+behavior+of+materials%22">Mechanical behavior of materials</searchLink><br /><searchLink fieldCode="DE" term="%22Machining%22">Machining</searchLink><br /><searchLink fieldCode="DE" term="%22Aluminum+alloys%22">Aluminum alloys</searchLink><br /><searchLink fieldCode="DE" term="%22Porosity%22">Porosity</searchLink><br /><searchLink fieldCode="DE" term="%22Tensile+strength%22">Tensile strength</searchLink><br /><searchLink fieldCode="DE" term="%22Surface+roughness%22">Surface roughness</searchLink><br /><searchLink fieldCode="DE" term="%22Manufacturing+processes%22">Manufacturing processes</searchLink>
– Name: Abstract
  Label: Abstract
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  Data: This study presents an integrated evaluation of the mechanical properties and machinability of thin-walled aluminium alloys fabricated via Wire Arc Additive Manufacturing (WAAM), comparing them against conventional wrought counterparts. Experimental investigations were conducted through tensile testing, hardness measurement, surface characterisation, and cutting force analysis. The results reveal a critical performance trade-off: WAAM specimens demonstrated superior bulk mechanical properties, most notably a 44.36% increase in tensile strength, alongside enhanced elongation despite a marginal reduction in hardness. However, this structural advantage is counterbalanced by a significant machinability penalty. Frequency domain analysis using Power Spectral Density (PSD) revealed that inherent microstructural porosity in WAAM components triggers dynamic instabilities during machining. These irregularities make the material highly susceptible to high-frequency chatter, ultimately resulting in a 46.73% increase in surface roughness. By establishing a direct relationship between fabrication-induced microstructural defects and dynamic machining degradation, these findings emphasise the necessity for defect-aware, optimised hybrid manufacturing strategies to improve the industrial applicability of WAAM-fabricated structures. [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/ma19122653
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        Text: English
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        PageCount: 19
        StartPage: 2653
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      – SubjectFull: Mechanical behavior of materials
        Type: general
      – SubjectFull: Machining
        Type: general
      – SubjectFull: Aluminum alloys
        Type: general
      – SubjectFull: Porosity
        Type: general
      – SubjectFull: Tensile strength
        Type: general
      – SubjectFull: Surface roughness
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      – SubjectFull: Manufacturing processes
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      – TitleFull: Comparative Evaluation of Mechanical Behaviour and Machinability of WAAM-Fabricated Aluminium Alloys.
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              M: 06
              Text: Jun2026
              Type: published
              Y: 2026
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