Arc-DED additive manufacturing of high-Zn-content Al-Zn-Mg-Cu alloy assisted by interlayer remelting and mechanical hammering

The development of high-strength aluminum alloys is crucial for optimizing the performance of these Arc-DED-manufactured components. However, achieving a high tensile strength remains a major challenge for Arc-DED fabricated aluminum alloys.

In this work, high-Zn-content Al-Zn-Mg-Cu alloys were fabricated by Arc-DED, with a small amount of TiC and Al₃Ti introduced for grain refinement. In-situ Zn alloying elevates the Zn content to over 9 wt.%, which plays a dominant role in achieving the ultra-high strength. During the Arc-DED process, in-situ Zn alloying is achieved by pre-positioning Zn foil on the top surface of each deposited layer.