Microstructure and corrosion resistance of CMT+P wire arc additive manufacturing 2024 aluminum alloy

As-deposited parts of 2024 aluminum alloy are fabricated by cold metal transfer and pulse （CMT+P） hybrid wire arc additive manufacturing. The distributions of pore defects， grain morphology， and secondary phase precipitation of CMT+P wire arc additive manufacturing 2024 aluminum alloy， and the influence of different process parameters on pore defects， grain morphology and secondary phase precipitation， and corrosion resistance are investigated. The results show that the pores of the as-deposited parts of 2024 aluminum alloy are mainly distributed near the fusion line. In the same heat input， the larger wire feed speed and travel speed result in higher porosity. In a deposition layer， the upper part is the equiaxed grain without preferred orientation， and the lower part is the columnar grain with preferred orientation. In the same heat input， the texture is weakened and the percentage of equiaxed grains is increased due to the fine grain region in the higher wire feed speed and travel speed. The precipitated secondary phases are mainly Al2CuMg， Al2Cu， and rich-Fe， Mn phases. The secondary phases distribute continuously along the grain boundaries. In the early stage of corrosion， the main factor affecting the corrosion resistance of as-deposited parts is the precipitation amount of Al2CuMg. The better local corrosion resistance is mainly caused by lower Al2CuMg phase fraction in lower wire feed speed and travel speed.