Characterisation of structural modifications on cold-formed AA2024 substrates by wire arc additive manufacturing

Mathias Silmbroth*, Norbert Enzinger, Christian Schneider-Bröskamp, Aurel Arnoldt, Thomas Klein

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review


Wire arc additive manufacturing, employing conventional fusion welding processes, shows excellent versatility and can therefore be used for structural modifications of existing parts to create hybrid components. This study evaluates the modification of cold-formed AA2024 metal sheets with 2xxx filler metals to produce 2xxx hybrid structures. The alloys are investigated by thermodynamic simulations and the solidification crack susceptibility is assessed by calculating the index for hot cracking susceptibility. Using cold metal transfer, single-layer depositions are generated on profile sheets after which the specimens are characterised by three analysis procedures: metallographic analysis, chemical analysis, and hardness testing. Results indicate that AA2024 wire material, although generally considered difficult to weld, is more suitable for the additive modification of AA2024 sheets and profiles, as crack-free specimens can be deposited on cold-formed substrates.

Original languageEnglish
JournalScience and Technology of Welding and Joining
Publication statusE-pub ahead of print - 2022


  • AA2024
  • aluminium alloys
  • hybrid components
  • liquation cracking
  • solidification cracking
  • stiffeners
  • Wire arc additive manufacturing

ASJC Scopus subject areas

  • Materials Science(all)
  • Condensed Matter Physics

Fields of Expertise

  • Advanced Materials Science

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