Influence of Temperature on Deformation and Damage Mechanisms of Wire + Arc Additively Manufactured 2219 Aluminum Alloy

This work investigates the deformation and damage mechanisms of wire + arc additive manufacturing (WAAM) 2219 aluminum alloy over a broad temperature range of 77 K to 523 K. It is found that the strength and work hardening rate increase significantly with decreasing the temperature from 523 K to 77 K, and the fracture mode transitions from transgranular fracture mode to a mixture of intergranular and transgranular fracture ones. The large elongations to fracture are very similar for the specimens tested at 77 K and 523 K. This is mainly attributed to higher uniform elongation before necking at 77 K and higher post-necking elongation at 523 K. The cracking of alpha-Al + theta (Al2Cu) eutectics is the primary mechanism of micro-void nucleation, independent of the test temperature. The nucleated micro-voids, along with larger gas pore defects introduced by WAAM, extend along the tensile direction. In addition, as the temperature increases from 77 K to 523 K, the fracture mechanism transitions from high strain localization to extensive necking, leading to higher dislocation density, more grain fragmentation and micro void nucleation, and more significant grain elongation and void growth. True stress and strain responses over the studied temperature range (77 523 K) and strain rate range (0.0001 0.01 s- 1) are well predicted using an improved Arrhenius-type constitutive model, by considering the activation energy of deformation as a function of temperature.